InPowert Pro

G-Drive
User’s Guide
 ABOUT THIS INPOWERt PRO USER’S GUIDE
This InPower Pro User’s Guide is a supplement to the InPower User’s Guide (3397100–04). Refer to
the InPower User’s Guide for basic service procedures. This supplement covers the calibration
download features that are used to install or update the calibration file in the ECM (Electronic Con-
trol Module).
This software is subject to change and upgrades, which may not be reflected in this manual. In cases
where this manual and the software conflict on features and/or operation methods, the software will
take precedence. No part of this document may be reproduced or transmitted in any form or by any
means, electronic or mechanical, for any purpose, without express written permission of Cummins
Power Generation.
SOFTWARE REGISTRATION
NOTICE! Both new and current InPower user’s must register the InPower 4.0 software. The
serial number required for registration must be obtained from the install program. Do not use
the serial number printed on the dongle label for registration.
You can obtain the Registration Password by calling the Cummins Solution Center at
1.877.377.4357 (1.812.377.4357 outside the toll-free area) or by registering online using the InPow-
er registration intranet site at: wwwi.onan.com listed under Onan Systems – InPower. The web site
is password protected and it requires a User Name (wwid) and Password (http password). Instruc-
tions for setting up your http password are located at: wwwi.onan.com listed under Onan Systems –
Getting Started. Setting up an http password can take up to 24 hours.

SERVICE AND SUPPORT

Beginning in March of 2004 support for this product will transition to the Cummins Solution Center.
If you are having a problem with the software, write down what you can about the problem before
contacting the Solution Center. Determine whether the problem can be repeated. Have the software
version available (this can be found in the Help–About window). To receive support and service
information for InPower, call this number:
Phone: 1.877.377.4357 (outside the toll-free area call 1.812.377.4357)
For users with access to the Cummins intranet, you may enter a Problem Ticket:
Launch your internet browser and enter http://help.cummins.com in the Address/Location
Click on Problem Ticket
Enter your Cumnnins id (wwid/Racifid) Click on the Submit button
In the Resource Class select PowerGen Electronic Tools
In the Resources filed select InPower
Fill in the Ticket Summary, the Detail field, and the contact information
Click on the Submit Ticket button
E 2004 Onan Corporation. All rights reserved.
Onan is a registered trademark of Onan Corporation.
Cummins is a registered trademark of Cummins Inc.
InPower is a trademark of Onan Corporation.
Windows is a registered trademark of Microsoft.

i
 ONAN INPOWER SOFTWARE LICENSE AGREEMENT

By breaking the seal on the InPower CD Package, you indicate your acceptance of the Agree-
ment. If you do not accept the terms of this Agreement, you may return, within 5 Business days of
your purchase, the entire contents of this kit, to the Onan distributor from which it was purchased
for a complete refund.

Refer to InPower User’s guide 3397100–04, available online in the InPower program group, for
a recital of the license agreement. All terms and conditions of the software license agreement
fully apply to this InPower Pro software version.

ii
Table of Contents
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About InPower Pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
InPower Pro Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
PC Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
About this User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. INITIAL CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
About Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Calibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Writing Adjustments from a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Final Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3. UPDATE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
About Update Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Update Calibration Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Update Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

iii
NOTES

iv
 1. Introduction
ABOUT INPOWER PRO INPOWER PRO FEATURES
When the InPower Pro service tool is con-
InPower Pro is used to download calibration nected to a device, two new features are added
software into the Electronic Control Module to the Device menu; Initial Calibration and Up-
(ECM). The features used to perform these date Calibration (Figure 1-1).
functions are called Initial Calibration and Up-
date Calibration. This guide describes how to
use the InPower Pro service tool to perform
both of these functions.
Disconnect
Calibration files are provided on the Power
Generation INCAL CD. Always use the most Print Selected Features CtllĆP
recent calibration file. Beginning with the re-
lease of InPower 4.0, the InPower program and
the INCAL CD time–out based on a subscrip- Clear Faults
tion schedule.
Capture to file...
The generator-drive, or G-Drive Control Sys-
Initial Calibration...
tem (GCS), uses an application controller
called an Electronic Control Module or ECM. Update Calibration...
The term device is used to describe an applica-
FIGURE 1-1. DEVICE MENU
tion controller, like the ECM. The service PC,
running InPower Pro, is connected to the de- Initial Calibration
vice via an RS-232 serial communications The Initial Calibration feature is used to down-
null-modem cable. load the calibration file into a service replace-
ment ECM. This procedure is described in
InPower Pro provides all of the service fea-
Section 2.
tures included in the standard InPower prod-
uct, plus it provides the Calibration Download Update Calibration
features. Thoroughly review the InPower The Update Calibration feature is used to up-
User’s Guide (3397100–04), available online date the calibration files in an ECM to a newer
in the InPower program group, prior to using calibration file version. This procedure is de-
this InPower Pro User’s Guide. scribed in Section 3.

1-1
 PC REQUIREMENTS
InPower Pro requires one of the following op-
erating systems: Microsoft Windows 98, Win-
dows 98SE, , Windows 2000, Windows Me,
Windows NT 6.0 or Windows XP. Refer to the
InPower User’s Guide (3397100–04) for a
complete description of the recommended op-
erating system.

SYSTEM SECURITY PC With InPower Pro

Security
InPower is available in two kits, one with cal- Dongle
ibration download capability (InPower Pro)
and one without calibration download capabil-
ity (InPower). To provide software security, FIGURE 1-2. SECURITY DONGLE
each InPower product is packaged and
installed separately, and each one has a unique The dongle must be attached to the parallel
serial number and registration password. port prior to InPower Pro use. The dongle is
A hardware security lock, referred to as a used to store the InPower Pro product serial
dongle, provides security for InPower Pro. The number and registration password.
dongle prevents unauthorized copying of the Connection to the PC’s parallel port can be
software and unregistered access to a device. made through the dongle. The dongle will not
To prevent damage to the dongle, always interfere with use of the parallel port for other
connect it to the PC when the power is Off. applications, like printing.

1-2
 USER INTERFACE Last minute software changes and corrections
to this User’s Guide may be found in the Read-
InPower Pro software operates in the Windows Me file.
graphical environment and is compatible with
Section 1 provides a general InPower Pro sys-
Windows. You can access InPower Pro
tem overview.
through the Start menu. If you are unfamiliar
with Windows, or have questions, refer to the Section 2 describes how to download an initial
Microsoft Windows User’s Guide for your spe- calibration into an ECM.
cific operating system, or click on Help, from Section 3 describes how to update an existing
the Windows Start menu, to view the Win- calibration file in an ECM.
dows Help Topics.
InPower Pro uses the Windows Explorer tree WARNING
hierarchy for navigating a connected file or de- Electrical equipment and engines present haz-
vice (referred to as Device Explorer, in InPow- ards that can result in property damage, severe
er Pro). personal injury or death. The InPower Pro tool
The tool’s main window displays a Menu Bar is for use by trained and experienced techni-
and a Toolbar for access to the tool’s functions. cians only. Refer to the equipment’s Opera-
Only commands applicable to the current ac- tor’s Manual for important safety precautions.
tive window are enabled, all other commands
WARNING Electrical shock and moving
from the Menu Bar or Toolbar are grayed out.
parts can cause severe personal injury or
ABOUT THIS USER’S GUIDE death. Notify personnel before starting a gen-
erator set and before performing load trans-
This User’s Guide covers procedures for the fer on a transfer switch. Refer to the equip-
Initial Calibration feature and the Update Cal- ment Operator’s Manual for important safety
ibration feature. precautions.

1-3
NOTES

1-4
 2. Initial Calibration
ABOUT INITIAL CALIBRATION The service PC, running InPower Pro, is con-
nected to the device via an RS-232 serial com-
The Initial Calibration feature is used to down- munications null-modem cable. Figure 2-1 il-
load a calibration file into a service replace- lustrates the method used to connect the ser-
ment Electronic Control Module (ECM). This vice PC, via the engine harness, to the device.
section covers the procedures for performing
an Initial Calibration. The serial cable is connected to the (COM)
port on the PC with a DB9 connector. The other
INITIAL CALIBRATION SETUP end of the serial cable uses a 9-Pin Deutsch
connector.
Connecting to an ECM CAUTION Improper calibration can
You must connect the service PC to the ECM to cause equipment malfunction or damage.
perform either the Initial Calibration proce- Adjustments must be performed by trained
dure or the Update Calibration procedure. and experienced personnel only.

Connects To
Engine Harness

Service Cable
DB9 to 9-Pin Deutsch
(CUMMINS P.N. 3163156)
PC With InPower Pro
Security
Dongle

FIGURE 2-1. INPOWER PRO SERIAL CONNECTION (TYPE 1 CONNECTION BOX )

2-1
 INITIAL CALIBRATION To prevent damage to the dongle, always
connect it to the PC when the power is Off.
Use of a Capture File can reduce the amount of Connect the serial communication cable from
adjustment that may be required when replac- the service PC to the device, as shown in Fig-
ing the ECM. If the old ECM is operational, ure 2-1.
and a capture file has not already been created,
correct any active faults (if possible). Create a Start InPower Pro and launch the Alarm Popup
Capture File following the procedure de- Window by clicking on the firecracker icon,
scribed in the Capture File section of the In- located on the lower right corner of the Win-
Power User’s Guide. dows status bar. Click on the Alarm Popup Op-
tions menu, then click on AutoAnnounce to
Refer to the service manual for control replace- deselect (uncheck) it. Disabling this feature
ment procedures. Before replacing the control, prevents nuisance alarms during the calibra-
remove power from the battery charger and tion download.
block heater, if equipped, then remove power
Connect to the port by double clicking on the
from the control.
port that matches the COM port on the service
Complete all necessary service replacement PC being used for the ECM connection
procedures and power the control. Reconnect (COM1, COM2, etc.). The available COM
power to the battery charger and block heater, ports are displayed in the Device Explorer di-
if applicable. rectory (left pane).
Make sure the dongle, provided with the In- Select the device DVC1 (or GCS, if the device
Power Pro software, is attached to the service already has a calibration file) by clicking on it
PC. (Figure 2-2).

FIGURE 2-2. MAIN WINDOW

2-2
 FIGURE 2-3. MAIN WINDOW

After connecting to the device, click on the De- Refer to the Dataplate, located on the side of
vice menu and click on Initial Calibration the ECM, for the electronic configuration (cal-
(Figure 2-3). ibration part number). See Figure 2-4.
If prompted to select between G-Drive and
Genset applications, select G-Drive, then se-
lect Next.

Calibration Part Number

ECM CODE 06000104

FIGURE 2-4. DATAPLATE

2-3
If a popup message indicates that there is an er- Selecting Calibration Part Number
ror loading from the INCAL CD, either the CD
drive letter was not correctly specified during After clicking on Initial Calibration, the Select
InPower Pro installation, or the CD is not
Calibration window is displayed (Figure 2-6).
installed or is defective. If the CD is in the CD
This feature lists the calibration files (ECM
drive, click on Yes, and specify the correct CD
drive designation. If the CD is not in the drive, Codes) that are available from the Power Gen-
insert the CD and click on No. eration INCAL CD. Also shown are the En-
gine Control Parts List (CPL) and other related
application descriptions.
Refer to the Dataplate, located on the side of
the ECM, for the electronic configuration
(ECM Code). See Figure 2-4.
Use the scroll bar to locate the ECM Code that
FIGURE 2-5. FIND INCAL
matches the number shown on the Dataplate
(Figure 2-4). The data, displayed in each col-
The INCAL CD location can be verified by umn, can be sorted in ascending or descending
clicking on the Port menu and clicking on order by clicking on the column heading.
Find InCal (Figure 2-5). Select the INCAL
CD drive designation from the drop-down list, Select the matching calibration part number by
then click on Verify INCAL Structure. A clicking on it. When the matching calibration
popup message will verify the INCAL loca- part number is selected, click on Next to con-
tion. tinue the initial calibration.

FIGURE 2-6. SELECT CALIBRATION

2-4
 FIGURE 2-7. HISTORY

History If the History window displays the calibration

file part number that was previously selected,
The History window (Figure 2-7) displays the click on the Next button to proceed to the Save
Revision History, Calibration File (part num- and Restore Parameters feature.
ber) and Revision Description.
Save and Restore Parameters
If the History this window displays a calibra-
tion file that does not match the calibration file The Save and Restore Parameters window dis-
on the Dataplate, click on the Back button to plays the Parameter Descriptions, Value and
choose the correct calibration file. Units of measure information (Figure 2-8).

FIGURE 2-8. SAVE AND RESTORE PARAMETERS

2-5
Use Capture File Feature select the file, then click on the OK button
(Figure 2-9). Using a capture file, during an
Click on the Set Data Plate From Capture initial calibration, will only restore the data-
File button to select the capture file created plate information. To restore the remaining
from the previous ECM (if available). capture file parameter settings, click on the
box next to the Overlay Capture File After
Calibration. If this feature is not used, the cap-
ture can still used after performing the initial
calibration to overwrite the parameter settings.
The Save and Restore window will display the
capture file name selected (Figure 2-10).
Verify that the information displayed in the pa-
rameter list matches the information shown on
the data tags. Use the scroll bar to review all of
the information. If any information needs to be
FIGURE 2-9. MAIN WINDOW
corrected, double click on the data and enter
the correct information.
If using the Set Data Plate From Capture File When the correct information is displayed,
button, browse to the Capture file location and click on the Next button.

FIGURE 2-10. CAPTURE FILE SELECTED

2-6
 FIGURE 2-11. FEATURE LIST

Feature List
The Feature List window is displayed (Figure
2-11) following the Save and Restore Parame-
ters window. Feature selection is not used with
G-Drive applications. Click on the Finish but-
ton to continue.
If all of the information has been entered cor-
rectly, a popup window prompts the user with FIGURE 2-13. FEATURE LIST
the question “Do you wish to calibrate the con-
troller now?” (Figure 2-12). Click on the Yes
button to continue. Next, a popup window informs the user that the
calibration file download will erase all adjust-
ments and prompts the user with the question
“Do you choose to continue?” (Figure 2-13).
Click on the Yes button, to begin the initial cal-
ibration download.
Note: Popup messages may be displayed be-
hind an open window. To view all open win-
dows, including popup messages, hold down
the Alt key and repeatedly press the Tab key
FIGURE 2-12. CALIBRATION POPUP to view each open window.

2-7
Calibration Download still does not work, record any the error mes-
sages and contact the Service and Support
The calibration file download may take up to number listed in the front of this user’s guide.
20 minutes, depending on the service PC and
the communication port. WRITING ADJUSTMENTS FROM
During the download, it is normal operation A CAPTURE FILE
for the control display (if equipped) to display
warnings. Do not hit the “Fault Acknowl- If a capture file was made prior to the control
edge” button during the calibration file down- being replaced, and the Overlay Capture File
load, or the download may be interrupted. After Calibration feature was not used the,
the capture can still used after performing the
When the download is complete, a final popup initial calibration. The previous parameter ad-
message informs the user of the download sta- justments and settings, stored in the capture
tus (Figure 2-14). If the download completed file, can be written to the new control (device).
successfully, click on the OK button to close Refer to the Capture File section in the InPow-
the popup message. er User’s guide (3397100-04). Follow the pro-
cedures described under Writing to a Device.

FINAL ADJUSTMENTS
Prepare to start the genset and test the opera-
tion of the entire system. Refer to the service
manual for adjustment procedures and observe
all safety precautions described in the service
FIGURE 2-14. FEATURE LIST manual.
After completing all necessary adjustments,
If the popup message indicates that the down- make a new capture file. Store a copy of the
load was not successful, perform the Initial capture file at the site and return a copy to Ser-
Calibration procedure again. If the procedure vice for cataloging.

2-8
 3. Update Calibration
ABOUT UPDATE CALIBRATION CAUTION Improper calibration can
cause equipment malfunction or damage.
The Update Calibration feature is used to re-
Adjustments must be performed by trained
place a current calibration file with a newer
and experienced personnel only.
version from the Power Generation INCAL
CD. The new calibration file is written over the Make sure the dongle, provided with the In-
current calibration file, in the ECM. Power Pro software, is attached to the service
Calibration updates are performed at the site PC.
using InPower Pro. This section covers the To prevent damage to the dongle, always
procedures for performing Update Calibra- connect it to the PC when the power is Off.
tion.
Connect the serial communication cable from
UPDATE CALIBRATION SETUP the service PC to the device, as shown in Fig-
ure 2-1.
You must connect the service PC to the ECM in Start InPower Pro and launch the Alarm Popup
order to perform the Update Calibration proce- Window by clicking on the firecracker icon,
dure. Connection between the service PC and located on the lower right corner of the Win-
the ECM is made with a special RS-232 serial dows status bar. Click on the Alarm Popup Op-
null-modem cable. tions menu, then click on AutoAnnounce to
Refer to Section 2, Figure 2-1, for the connec- deselect (uncheck) it. Disabling this feature
tion procedure. The serial cable from the ser- prevents nuisance alarms during the calibra-
vice PC is connected to the engine harness. tion download.

3-1
 FIGURE 3-1. MAIN WINDOW

Connecting to the Device UPDATE CALIBRATION

After connecting to the device, click on the De-
Connect to the port (COM1, COM2, etc.) that vice menu and click on Update Calibration
matches the COM port on the service PC being (Figure 3-2). If prompted to select between G-
used for the ECM connection. The available Drive and Genset applications, select G-
COM ports are displayed in the Device Explor- Drive, then select Next.
er directory (left pane). Double click on the If prompted with the message, “Could not find
COM port (or click on the COM port and then a matching Calibration Part Number ...,” click
click on the Connect button, on the toolbar). on the OK button. Use the Initial Calibration
feature (Section 2) to update the calibration
Select the device (GCS) by clicking on it. De- file.
vice Explorer displays the features that are After selecting Update Calibration, the His-
available for the device Figure 3-1. tory window is displayed.

FIGURE 3-2. UPDATE – DEVICE MENU

3-2
 FIGURE 3-3. HISTORY

History

The History window displays information

about the currently installed calibration part
number and calibration revision across the top
of the window (Figure 3-3).
History also displays information from the
Power Generation INCAL CD about the Revi- FIGURE 3-4. UPDATE NOW
sion History, Calibration File part number and When the download is complete, a final popup
Revision Description. message informs the user of the download sta-
The Save and Restore checkbox is used to tus. If the download completed successfully,
save the current adjustment trims and settings. click on the OK button to close the popup mes-
Make sure the checkbox is enabled (checked) sage (Figure 3-5).
before proceeding. If the popup message indicates that the down-
load was not successful, perform the Update
Click on the Finish button to proceed with the Calibration procedure again. If the procedure
calibration update. still does not work, record any the error mes-
If a newer calibration is available with INCAL, sages and contact the Service and Support
a popup window prompts the user with the number listed in the front of this user’s guide.
question “Do you wish to calibrate the control-
ler now?” (Figure 3-4). Click on the Yes button
to continue.
Note: Popup messages may be displayed be-
hind an open window. To view all open win-
dows, including popup messages, hold down
the Alt key and repeatedly press the Tab key
to view each open window. FIGURE 3-5. COMPLETED

3-3
NOTES

3-4
Cummins is a registered trademark of Cummins Inc.
InPower is a Trademark of Onan Corporation
Powerful Solutions is a trademark of Onan Corporation
InPower Version 4.0
Bulletin Number 3397103-04
 Supplement for Inpower 5.0
CORE II ECS SUPPORT drop-down list. Select ECS Configuration
from the Protocol drop-down list. Enter a Site
InPower Pro version 5.0 supports Core II ECS .
ID. Use the drop−down arrow to select the
The ECS (ECM) device that is currently sup-
Adapter type and COM Port. Click on the
ported is the ECS model CM850.
OK button to create the new site (Figure 1).
This supplement describes the InPower Setup
With Core II ECS selected in the Site List,
and Operation for Core II ECS (ECM) devices.
note that the Device Setup button is disabled.
Writing calibration files to this device is not A device setup is not necessary with this site
supported in version 5.0. type.
CORE II ECS DEVICE SETUP
Refer to Section 2 of this G-drive user’s Guide
for a general description of the Setup feature.
Make sure that the network adapter drivers are
installed (supplied by adapter manufacturer)
prior to performing this setup.
Launch the Setup program from the Start
menu − Power Generation − InPower pro-
gram group.
In this example a new site will be created spe-
cifically for connecting to a Core II ECS
(ECM) device.
Select the Site Setup tab and then click on the
Add button, located below the Site List.
Create a new site for connecting to the Core II
ECS. Select the Site Type Network, from the FIGURE 1. CORE II ECS SITE SETUP

1
 FIGURE 2. CONNECTION TO CORE II ECS (ECM)

CORE II ECS OPERATION the Core II ECS. When connected to an ECS

(ECM) the name of the device node is dis-
Refer to Sections 3 and 4 in the G−Drive User’s played in Module Name (Node ID) format. Re-
Guide for information on using InPower to fer to Figure 2.
connect to a device.
In this example we will run an Engine Protec-
InPower Pro version 5.0 support operation for tion Witness Test.

2
 FIGURE 3. OPERATION WITNESS TEST FEATURE

After connecting to the ECS (ECM) select the will launch the Operation Run Witness Test
Engine Protection Witness Test feature and dialog as shown in Figure 3. For operations
refer the Parameter list. Figure 2. that require an input, select the the input pa-
To run the Engine Protection Witness Test fea- rameter and click on Execute, to execute the
ture, double click on runWitness Test, this operation.

3
NOTES