PowerCommand Simulator – 300-5416

Scope
This document describes the operation of the 300-5416 PowerCommand simulator and provides
simulator part numbers and calibration software information.

Description
The power command simulator 300-5461 is designed for use with the PowerCommand 2100,
3100 and 3200 controls. It is designed to simulate the alternator and engine functions of a typical
hydro-mechanical generator set. Not all switch functions are supported on all controls.

Required hardware and software

To use the simulator with a control it is necessary to have the proper control, harness and
software. The part numbers for these items are listed below.

The simulator identifies which control it is connected to by the harness that is plugged in to it. If
you change harnesses to use the simulator with a different control it is necessary to cycle power
to the simulator for the simulator to recognize the new control.

The PCC 2100 and 3200 controls must have the proper calibration software loaded to operate
with the simulator. This software is available on the InCal CD and can be downloaded with the
InPower service tool. Labels on the side of the controls indicate the features, serial number and
checksum that must be used to download the calibration. The information on the labels is also
listed on the last page of this document along with additional notes on downloading calibrations.

PCC 2100:
Item Part number
PowerCommand 2100 Training Control 0300-5528
PowerCommand 2100 Harness 0338-4053
PowerCommand 2100 software 0326-5613
Note: The PCC 2100 training control is modified for use with the simulator only. It cannot be used
on a genset.

PCC 3200:
Item Part number
PowerCommand 3200 Operator Panel 0300-5313-01
PowerCommand 3200 Card Cage 0300-5563
PowerCommand 3200 Harness 0338-4055
PowerCommand 3200 software 0326-5612
Note: The PCC 3200 control does not use a fuel card. The genset card is moved from slot 2 to
slot 0. This is the hydro-mechanical configuration of the PCC 3100 which currently is not used in
production.

PCC 3100:
Item Part number
PowerCommand 3100 Control PCUK121-1A
PowerCommand 3100 Harness 0338-4054
Note: The PCC 3100 control used with the simulator is a standard 24V paralleling control used
with hydro-mechanical fuel systems. Standard software is used.

Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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 PowerCommand Simulator – 300-5416

Simulator function description

REMOTE START COMMANDS

CRANK RUN

REMOTE START NON-EMERGENCY START

ON ON

OFF OFF

Crank LED - Indicates that the control has attempted to engage the starter. When the simulator
sees this input active it provides a 200 rpm input to the control unless the FAIL TO CRANK or
MAG PICKUP switches are on.

Run LED - Indicates the run relay has closed (fueling has been enabled). When the simulator
sees this input, governor and regulator simulation is activated.

REMOTE START switch - Provides a remote start to the genset. The control RUN/OFF/AUTO
switch must be in AUTO when this is used.

NON-EMERGENCY START switch - Used on PCC 3200 only. When this switch is on and the
remote start switch is turned on, the control will go through a warm-up at idle sequence before
starting. The control RUN/OFF/AUTO switch must be in AUTO when this is used.

MONITOR POINTS
REGULATOR GOVERNOR
PWM PWM

MAGNETIC
PICKUP

The monitor points are used to provide access to the governor and regulator drive and magnetic
pickup signals while the control is running. The signals can be observed with a multimeter or
oscilloscope. The magnetic pickup is the speed input to the control. It is proportional to the speed
of the generator. The frequency of the magnetic pickup signal is a function of the number of teeth
on the flywheel. The regulator and governor PWM monitor points are the drive signals provided to
the simulator from the control that tell the simulator what speed or voltage to operate at. They are
pulse width modulated signals whose pulse width changes as the speed or voltage change.
Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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 PowerCommand Simulator – 300-5416

FAULT SIMULATION
FAIL TO MAG PICKUP OIL SENSOR
CRANK FAILURE OVERCRANK LOW COOLANT FAILURE OVERSPEED

NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL

CUSTOMER LOW FUEL COOLANT LOW ENGINE

OVERVOLTAGE UNDERVOLTAGE FAULT LEVEL SENSOR TEMPERATURE

NORMAL NORMAL NORMAL NORMAL NORMAL NORMAL

The fault simulation simulates some of the common GENSET faults. They are described below.

Fault Description
FAIL TO CRANK When activated disables the speed input to the control when a crank signal is
received. Simulates the engine not cranking.
MAG PICKPUP FAILURE When activated magnetic pickup speed input to the control to set to zero RPM.
OVERCRANK When activated prevents run input from enabling the governor or regulator.
Simulates the engine cranking but not starting.
LOW COOLANT When activated grounds the low coolant switch input to the control
Not supported on PCC 3200
OIL SENSOR FAILURE When activated an oil pressure sensor failure is simulated.
OVERSPEED When activated forces high speed on the magnetic pickup speed input to the
control.
OVERVOLTAGE When activated forces high AC voltage on the control AC sense inputs. Note: If
the control AC voltage setting is set too high the voltage may not be high
enough to activate an over voltage fault.
UNDERVOLTAGE When activated forces low AC voltage on the control AC sense inputs.
LOW FUEL LEVEL When activated grounds the low fuel sensor input on the control.
COOLANT SENSOR When activated a coolant temperature sensor failure is simulated.
CUSTOMER FAULT When activated grounds the customer fault input on the control.
Not supported on PCC 2100
LOW FUEL LEVEL When activated grounds the low fuel level fault input on the control.
Not supported on PCC 2100
COOLANT SENSOR When activated a coolant temperature sensor failure is simulated.
LOW ENGINE When activated grounds the low engine temperature fault input on the control.
TEMERATURE Not supported on PCC 2100 or 3200 – use coolant temperature
potentiometer

Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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 PowerCommand Simulator – 300-5416

ENGINE FUNCTIONS

OIL PRESSURE COOLANT TEMP

The engine oil pressure and temperature can be adjusted using the appropriate potentiometers.

ALTERNATOR FUNCTIONS

CURRENT POWER FACTOR

The generator load can be adjusted using the current and power factor potentiometers. These
adjustments are not available when the simulator is in the utility paralleling mode.

Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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 PowerCommand Simulator – 300-5416

PARALLELING FUNCTIONS
BUS BUS VOLTAGE PHASE ROTATION UTILITY BREAKER BUS FREQUENCY
ON REVERSE OPEN

OFF NORMAL CLOSED

Note: The paralleling functions are only supported on the PCC 3100 and 3200 controls.

The simulator is capable of simulating all the functions of a paralleling system, synchronizing,
breaker control, load sharing and load governing. Bus voltage and frequency can be adjusted
with potentiometers and can be turned on and off with a switch to simulate closing to a dead bus.
The simulator will simulate operation of the generator breaker by receiving a breaker close signal
from the control and providing the breaker position input to the control. The simulator also
provides a “first start” signal to the control.

The bus voltage and frequency can only be adjusted when the generator circuit breaker is open.
Once the simulator receives the breaker close signal from the control the bus voltage and
frequency are fixed.

If the generator breaker is closed and the UTILITY BREAKER switch is in the closed position the
control is in the load govern (utility paralleling) mode. The base load setting in the control then
determines the load on the set. The current and power factor control potentiometers no longer
have any effect. When the simulator enters the load govern mode it may take several seconds
for the load to stabilize at the base load setting. Also the full adjustment range may not work for
the base load and power factor settings.

The phase rotation switch is used to simulate improper phase rotation of paralleled generator
sets. If the switch is in the reverse position the control will detect an incorrect phase rotation and
a fault will be displayed. This fault is only checked when the control has synchronized to the bus
and attempts to close the generator breaker.

Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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 PowerCommand Simulator – 300-5416

Software calibration information

The following are the labels that should be on the side of the PCC 2100 and 3200 training
controls. The information on the labels is required for downloading the simulator calibration with
InPower.

NOTE: When downloading a control the serial number A012345678 should be entered for the
genset serial number if it is not there. All the features should be selected prior to the download.
The PCC 2100 calibration is on the January 2002 InCal CD. The PCC 3200 calibration will be on
the May 2002 release.

PCC 3200 SIMULATOR

A012345678

09/28/2001 MMDDYY
0326-5612
0000

3415085 PARALLELING LEVEL:UTILITY MULTIPLE

3415087 APPLICATION RATING:STANDBY
3415091 RECONNECTABLE WYE
3415092 THREE PHASE ONLY
3415095 60HZ NOMINAL
3415115 LONWORKS CARD:YES
3415141 416V NOMINAL
3415152 VOLTAGE RANGE: 190/380-208/416
4054314 CT RATIO 7000:1
0x9b92 CHECKSUM

PCC 2100 SIMULATOR

A012345678

11/01/2001 MMDDYY
0326-5613 CALIBRATION PART NUMBER

0326-5482 FEATURE P/N

0326-5484 FEATURE P/N
0326-5488 FEATURE P/N
0326-5503 FEATURE P/N
0326-5565 FEATURE P/N
0326-5566 FEATURE P/N
0326-5570 FEATURE P/N
0326-5597 FEATURE P/N
0x93E4 CHECKSUM

Onan Corporation assumes no responsibility for any errors which may appear in this document nor does it make a commitment to update the information contained herein.
Onan retains the right to make changes to these specifications at any time without notice. No part of this document may be reproduced, translated, or transmitted in any form, or
disclosed to others without authorization from Onan Corporation.
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