Powercom Commissioning Guideline PDF
Powercom Commissioning Guideline PDF
2. Engine Ratings
Superceded
Part number Part description
part number
0338-4735 K6 harness
0338-4736 N14 Harness
0338-4737 V28 Harness
0338-4738 855 Harness
0338-4739 PT CT Harness
4105287 Calibration CD
Current transformers 380 kVA
Note: Part no. of ECPG engine harness and that of Powercom are different. Please
check before installation.
Note: The uppermost key on left side allows to return to the MAIN MENU.
Genset Running: This green LED is lit whenever the genset is running at rated rpm
Remote Start: This green LED is lit whenever the genset is remotely started.
Charging Failure: This red LED is lit when the battery fails to charge.
Low oil pressure warning: This orange LED is lit whenever the oil pressure is lower than
the normal operation.
Overspeed shutdown: This red LED indicates that engine has shutdown because of
excessive speed.
High coolant temperature warning: This orange LED is lit whenever the coolant
temperature reaches above normal range of operation.
Low coolant level shutdown: This red LED indicates that the engine has shutdown
because of low coolant level.
Warning: This orange LED is lit whenever the controller detects a warning signal.
Shutdown: This red LED is lit whenever the controller detects any shutdown fault.
3-way selector key switch: The 3 positions are:
Off: This prevents the engine from starting.
Run: This keeps the engine in the ready position so that once a start command is received,
the generator set starts.
Note: When key switch is in “Run” position, the genset will start automatically on
receiving the “Remote Start” command.
Crank: This key is used to crank the generator set.
Lamp key: Press and hold this button to test all front panel LEDs.
Idle & Rated speed: This key is used to run the generator set at idle or rated speed. The
state toggles with every press. The key is disable incase
• Genset Running on load
• Genset Started Remotely
Sample drawings related to each terminal of OEM connector are given below:
Applying +24 volts DC (with respect to engine battery negative) through an external contact at
Pin 4B, remote start LED glows.
Procedure: Connect Positive supply on pin 4B and ground at pin 1B
NOTE: The signal may be pulse or continuous.
¾ Remote Stop Signal (Pin no. 5B)
On applying +24 volts DC momentarily to pin 5B of connector B, the engine will shut down
remotely.
Procedure: Connect Positive supply on pin 5B and ground at pin 1B
NOTE: The signal may be pulse or continuous.
Frequency Adjust: Controller provides the user with 2 options for frequency adjustment.
The user can select “Raise-Lower Switches”, “Speed Bias Analog Input” or “None”
(from software C-view) as a source for providing the frequency adjustment. If the user
doesn’t want to adjust the engine speed then the “Speed Adjust Source” shall be set to
“None”.
“Raise Switch Signal” is provided on pin no.2B of connector B to increase the generator set
frequency. The frequency can be adjusted 4 Hz above the rated operating frequency.
As shown in the above example, the customer can implement this frequency adjust feature by
connecting the speed raise push button on connector B to +24 Volts. The engine speed will
increase by 1 RPM if the switch is momentarily pressed and released. If the switch is pressed
and held in that position then the engine speed will increase at a programmable rate (e.g. 2
RPM/ second).
Procedure: Connect Positive supply on pin 2B.
“Lower Switch Signal” is provided on pin no.3B of connector B to decrease the generator set
frequency. The frequency can be adjusted 4 Hz below the rated operating frequency.
The customer can implement this frequency adjust feature by connecting the speed lower push
button on pin 3B of connector B to +24 Volts which decreases the engine speed by 1 RPM.
For this, the switch should be momentarily pressed and released. If the switch is pressed and
held in that position then the engine speed will decrease at a programmable rate (e.g. 2
RPM/second).
Procedure: Connect Positive supply on pin 3B.
If the user wants to select the “Speed Bias Analog Input” as the frequency adjust source,
then the user first needs to enable the speed bias analog input by selecting “Connected”
option through Service Tool (C-View). Also the “Speed Adjust Source” parameter needs to
be configured to select “Speed Bias Analog Input” as the source for frequency adjustment.
The speed bias input can be implemented by connecting a 0-5 V (DC) to pin no. 6B of
connector B.
Procedure: Connect Positive supply on pin 6B and ground at pin 1B
Few faults can be configured through certain pin no.s of the OEM connector.
For example:
9 Pin no. 7B (Configurable discrete output 1):-
Configurable parameters:-
Common Warning
Common Shutdown
Engine Running, Engine Not Ready To Start,
High Coolant Temperature
Low Lube Oil Pressure
Over Speed
High Auxiliary Temperature
Low Coolant level, Over Voltage
Under Voltage
Over Frequency
Under Frequency
Over Current
High Optional Temperature
Time
Sr. Fault name Warning Shutdown Threshold Comments
no Threshold Threshold (sec)
Over voltage
1. Over voltage - 115% of rated 5 fault threshold
Under voltage
2. Under voltage 85% of rated - 5 fault threshold
Over frequency
3. Over Frequency - 110% of rated 5 fault threshold
Under
4. Under Frequency 85% of rated - 10 frequency fault
threshold
Over current
5. Over Current - 120% of rated 5 fault threshold
The datalink connector is 9 pin ‘D’ type connector interfacing with PC based
service tool. The data link is intended to be used to connect single or multiple PowerCom
to a host computer acting as a supervisor for facilitating data acquisition and logging using
a PC based service tool. There are many features of the PowerCom that are configured
using the service tool. Electronic service tool is a packaged software application that
installs on an IBM compatible PC. The Service Tool is available as a Kit (Part No.
4105287) on a CD. The Service PC, running the PowerCom Tool is connected to the
PowerCom via a RS-232 serial communication cable. The data link uses two wire RS-485
serial communication standard. A RS- 485 to RS-232 converter kit (Part No. 4071717) is
required for connecting the data link to a PC’s RS-232 serial communication port.
8.0 ALL POWERCOM’S DO NOT NEED CALIBRATION. THEY
ARE DUELY CALIBRATED. IF AT ALL REQUIRED THEN
FOLLOW THE FOLLOWING STEPS.
Calibration Procedure:-
5. A screen appears in which we have to select the type of controller and the engine
model. Then select *.cal file and select dash (-) for engine model and then press OK
for calibration.
6. Following screen appears on the PC when the controller is calibrating itself. It takes
around 10 to 15 minutes for calibration.
3. Now press the lower LHS key shown in the above figure; the ‘Enter ID’ option on
the monitor will start blinking.
4. If the engine model you want is not there on the screen then press key to
5. The model ID can be then selected by incrementing the ID values as per which
engine model it is to be calibrated for. Incrementing can be done by using the
upper RHS key and decrementing using the lower RHS key. For example, in the
figure below ID no.’4’ is selected for engine model no. KTA-1150-G.
6. This value can also be saved by pressing the lower LHS key.
7. The following screen will appear and the PowerCom will be calibrated for that
specific model.
Note: The model should appear on the screen while setting.
For example:
In the above screen, the ID entered is ‘1’, but the engine model with ID equal to 1 is
not displayed in the screen. So, in this case when we try to save this value it will not
get saved.
NOTE: - This setting changes only the display value of this parameter and not the real
alternator output value.