AUX101

Owner Owner Manual Controller AUX 101 AUX 102

English Original Instructions

5-2015

A030K737 (Issue 6)

Table of Contents 1. SAFETY PRECAUTIONS ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...........

1

2. INTRODUCTION.................... INTRODUCTION............................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................ ..... 2.1 About This Manual........... Manual ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ............... .... 2.2 AUX101.......................... AUX101..................................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................. ...... 2.2.1 AUX101 Inputs and Outputs ..................... ................................ ...................... ...................... ...................... ...................... ...................... ............. 2.2.2 AUX101 Inputs ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ..................... .......... 2.2.3 AUX101 Outputs ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .................. ....... 2.3 AUX102.......................... AUX102..................................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................. ...... 2.3.1 AUX102 Inputs and Outputs ..................... ................................ ...................... ...................... ...................... ...................... ...................... ............. 2.3.2 AUX102 Inputs ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ..................... .......... 2.3.3 AUX102 Outputs ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .................. ....... 2.4 Numbering Numbering of AUX102 Inputs Inputs and Outputs Outputs ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....

5 5 5 5 5 5 5 6 6 6 6

3. CHARACTER CHARACTERISTIC ISTICS S OF THE AUX 101 AND AUX 102 WITH VARIOUS VARIOUS CONTROLLERS ..................... ................................ ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ............... .... 3.1 Characteristics of the AUX 101 and AUX 102 with the PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ...................... ............. .. 3.1.1 Maximum Number of AUX 101/102 for the PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .............. ... 3.1.2 Required Required Part Numbers Numbers for for Operato Operatorr Panel Panel Softw Software are to Support Support the AUX 101.......... 101.......... 3.1.3 Possible Functions of AUX 101 Inputs for PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .............. ... 3.1.4 Default Functions of AUX 101 Outputs with the PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .............. ... 3.1.5 Possible Functions of AUX 102 Inputs for PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... .............. ... 3.1.6 Default Functions of AUX 102 Outputs with the PCC 1301, PCC 1302, and PowerCommand 1.x ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ............. 3.2 Characteristi Characteristics cs of the the AUX 101 101 and AUX AUX 102 with with the PCC PCC 2100....... 2100........... ........ ........ ........ ........ ........ ........ ........ .... 3.2.1 Maximum Maximum Number Number of AUX 101/102 101/102 for the the PCC 2100 ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ...... .. 3.2.2 Possible Functi Functions ons of AUX AUX 101 Inputs Inputs for PCC 2100 2100 ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 3.2.3 Default Functions Functions of AUX 101 Output Outputs s with the PCC PCC 2100 ........ ............ ........ ........ ........ ........ ........ ........ ...... .. 3.2.4 Possible Functi Functions ons of AUX AUX 102 Inputs Inputs for PCC 2100 2100 ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ....... ... 3.2.5 Default Functions Functions of AUX 102 Output Outputs s with the PCC PCC 2100 ........ ............ ........ ........ ........ ........ ........ ........ ...... .. 3.3 Characteris Characteristics tics of the the AUX101 AUX101 and and AUX102 AUX102 with with the the PowerCom PowerCommand mand 2.x and 3.x 3.x ........ ............ .... 3.3.1 Maximum Maximum Number Number of AUX101/102 AUX101/102 for the PowerComman PowerCommand d 2.x 2.x and and 3.x 3.x ........ ............ ........ ...... .. 3.3.2 Required Required Part Numbers Numbers to to Support Support the AUX101 for the PowerComma PowerCommand nd 2.x 2.x ........ .......... .. 3.3.3 Possible Possible Functi Functions ons of of AUX101 AUX101 Inputs Inputs for PowerC PowerComman ommand d 2.x and 3.x... 3.x....... ........ ........ ........ ...... 3.3.4 Default Default Functio Functions ns of AUX101 Outputs Outputs with with the the PowerCom PowerCommand mand 2.x 2.x and and 3.x..... 3.x......... ...... .. 3.3.5 Possible Possible Functi Functions ons of of AUX102 AUX102 Inputs Inputs for PowerC PowerComman ommand d 2.x and 3.x... 3.x....... ........ ........ ........ ...... 3.3.6 Default Default Functio Functions ns of AUX102 Outputs Outputs with with the the PowerCom PowerCommand mand 2.x 2.x and and 3.x..... 3.x......... ...... ..

10 10 10 11 11 12 12 12 12 13 13 17 17 18

4. HARDWARE ..................... ................................ ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................... ........

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4.1 AUX101 Board ...................................................................................................................... 4.1.1 AUX101 S1 ................................................................................................................ 4.1.2 AUX101 Device Number Indicator ............................................................................. 4.1.3 AUX101 Indicators ..................................................................................................... 4.1.4 AUX101 Connectors .................................................................................................. 4.2 AUX102 Board ...................................................................................................................... 4.2.1 AUX102 Indicators ..................................................................................................... 4.2.2 AUX102 Connectors .................................................................................................. 4.3 How to Install the AUX 101/102 Hardware........................................................................... 4.3.1 Wiring Diagrams Available......................................................................................... 4.3.2 Guidelines for Mounting the AUX 101/102 ................................................................ 4.3.3 Pin Connections for AUX101 Inputs 1-8 .................................................................... 4.3.4 Pin Connections for AUX102 Inputs 9-12 .................................................................. 4.3.5 Pin Connections for AUX101 Outputs 1-8 ................................................................. 4.3.6 Pin Connections for AUX102 Outputs 9-16 ............................................................... 4.3.7 Example of a Connection........................................................................................... 4.3.8 RTDs - About Four-wire Connections........................................................................ 4.3.9 Example of a Voltage Bias Connection with One Power Supply............................... 4.3.10 Example of a Voltage Bias Connection with Two Power Supplies .......................... 4.3.11 Example of a Speed Bias Connection ..................................................................... 4.4 Repairing Circuit Boards .......................................................................................................

19 19 19 20 20 27 27 28 31 32 33 34 34 34 34 35 36 37 38 38 39

5. CONFIGURATION OF THE AUX 101 AND AUX 102 WITH VARIOUS CONTROLLERS ......... 5.1 Tools to Configure a PCC 1301 or PowerCommand 1.x AUX 101/102 ............................... 5.1.1 About the I/O Module Menus ..................................................................................... 5.1.2 Using InPower to Configure the AUX 101 and AUX 102........................................... 5.2 Tools to Configure a PCC 2100 AUX 101/102 ..................................................................... 5.2.1 How to Disable or Enable an AUX 101 on the PCC 2100......................................... 5.2.2 How to Configure a Switch on the PCC 2100............................................................ 5.2.3 How to Configure a Voltage Bias on a PCC 2100..................................................... 5.2.4 How to Configure a Speed Bias on a PCC 2100....................................................... 5.2.5 How to Configure an Output on a PCC 2100 ............................................................ 5.3 Tools to Configure a PowerCommand 2.x or 3.x AUX101/102 ............................................ 5.3.1 How to Find the AUX101 Setup Screens in the Operator Panel ............................... 5.3.2 How to Configure a Switch on the PowerCommand 2.x or 3.x ................................. 5.3.3 How to Configure an Additional Function for AUX101 Inputs on the PowerCommand 2.x or 3.x .......................................................................................... 5.3.4 How to Configure an Analog Input on the PowerCommand 2.x or 3.x...................... 5.3.5 How to Configure an Output on the PowerCommand 2.x or 3.x ...............................

41 41 41 46 46 46 46 46 47 47 47 47 48 48 48 49

6. CONFIGURING THE AUX 101 AND AUX 102 WITH THE MCM3320........................................ 6.1 Supplementary Interface Device (SID) ................................................................................. 6.1.1 Generator Sets by SID............................................................................................... 6.1.2 Loads by SID ............................................................................................................. 6.1.3 SID Required.............................................................................................................. 6.1.4 Legacy SID Override (Before V2.00) ......................................................................... 6.1.5 Compatible Software Versions (AUX 101).................................................................

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6.1.6 Summary of Monitor Points (AUX 101/102)............................................................... 6.2 AUX101 Board ...................................................................................................................... 6.2.1 AUX101 S1 ................................................................................................................ 6.2.2 AUX 101 Device Number Indicator............................................................................ 6.2.3 AUX 101 Device Number by SID ............................................................................... 6.2.4 Changing the AUX101 Device Number ..................................................................... 6.2.5 AUX 101 Indicators .................................................................................................... 6.2.6 AUX 101 Connectors ................................................................................................. 6.2.7 AUX101 J1 ................................................................................................................. 6.2.8 AUX 101 J2................................................................................................................ 6.2.9 AUX 101 J3................................................................................................................ 6.2.10 AUX 101 J4.............................................................................................................. 6.2.11 AUX101 J5 ............................................................................................................... 6.2.12 AUX 101 J11............................................................................................................ 6.2.13 AUX101 J14 ............................................................................................................. 6.3 AUX102 Board ...................................................................................................................... 6.3.1 AUX 102 Indicators .................................................................................................... 6.3.2 AUX 102 Connectors ................................................................................................. 6.3.3 AUX 102 J1................................................................................................................ 6.3.4 AUX 102 J2................................................................................................................ 6.3.5 AUX 102 J3................................................................................................................ 6.3.6 AUX 102 J4................................................................................................................ 6.3.7 AUX102 J5 ................................................................................................................. 6.3.8 AUX102 J6 ................................................................................................................. 6.4 Connecting to an AUX 101 or AUX 102 Using InPower.......................................................

52 54 54 54 55 55 55 55 56 56 57 58 58 59 60 60 61 61 62 62 63 64 64 64 65

7. CONFIGURING THE AUX 101 AND AUX 102 WITH THE PC500/550 ...................................... 7.1 Configuring Modbus Communication Parameters ................................................................ 7.2 AUX101 Board ...................................................................................................................... 7.3 AUX 101 S1 Device Number ................................................................................................ 7.4 Configuring AUX 101 Using PC500/550 User Interface....................................................... 7.5 I/O Control Capabilities Over Modbus ..................................................................................

67 67 68 68 69 69

8. TROUBLESHOOTING ................................................................................................................. 8.1 DS1 and DS2 Are Off ........................................................................................................... 8.1.1 Checking the Power Connections.............................................................................. 8.1.2 Checking the Wires.................................................................................................... 8.1.3 Checking the Power Supply....................................................................................... 8.2 DS2 Is On ............................................................................................................................. 8.2.1 Checking the PCCNet Connections........................................................................... 8.2.2 Checking the Wires.................................................................................................... 8.2.3 Checking the Device to Which the Board Is Connected............................................

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9. MANUFACTURING FACILITIES..................................................................................................

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APPENDIX A. WIRING DIAGRAMS.................................................................................................

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Safety Precautions SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Before operating the generator set (genset), read the Operator's Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.

DANGER This symbol warns of immediate hazards which will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or product or pro perty damage. FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can result from improper practices. • DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. • DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. • Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel. • Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling propane to be trained and qualified. • Be sure all fuel supplies have a positive shutoff valve. • Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

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1. Safety Precautions

5-2015

EXHAUST GASES ARE DEADLY • Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust for leaks daily or per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. • The exhaust vent should be high enough to help clear gases, avoid accumulation of snow, and in accordance with local mechanical codes. • Be sure the unit is well ventilated. • Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Keep your hands, clothing, and jewelry away from moving parts. • Before starting work on the generator set, disconnect battery charger from its AC source, then disconnect starting batteries, negative ( -) cable first. In lean-burn natural gas (LBNG) gensets, also make sure the starter's air supply line is disconnected or completely vented until the generator set is ready to start. This will prevent accidental starting. • Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. • Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. • If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power Generation distributor for more information. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning. • Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. • Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure.

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• DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device. MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV) • Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. • Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded. GENERAL SAFETY PRECAUTIONS • Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved. • Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10). • Make sure that rags or combustible material are not left on or near the generator set. • Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit. • Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. • Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. • Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. • Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. • Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. • Wear hearing protection when near an operating generator set. • To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger system and exhaust system. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

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DISPOSE OF THIS UNIT PROPERLY

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Introduction

2.1

About This Manual This manual provides basic information about the AUX 101 and AUX 102. It explains how to install the AUX 101 and AUX 102 and how to configure various controllers to use them. This manual also provides reference information that can be used in advanced applications and in troubleshooting.

2.2

AUX101 The PowerCommand AUX101 provides additional inputs and additional outputs for auxiliary control and monitoring of the power system.

2.2.1

AUX101 Inputs and Outputs TABLE 1.

NUMBER OF INPUTS AND OUTPUTS ON THE AUX101

Description

Value

Number of Inputs

8

Number of Outputs

8

2.2.2

AUX101 Inputs An AUX101 input can be associated with a fault code. When the input is active, the fault is active. When the input is inactive, the fault is inactive, though the fault might have to be reset. Alternatively, some AUX101 inputs can be assigned specific input functions instead of a fault code. These functions have a variety of effects and vary by controller.

2.2.3

AUX101 Outputs Each AUX101 output is associated with a fault code. When the fault is active, the output is active. When the fault is inactive, the output is inactive.

2.3

AUX102 The PowerCommand AUX102 provides additional inputs and additional configurable outputs for auxiliary control and monitoring of the power system.

NOTICE The AUX102 requires the AUX101.

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2. Introduction

2.3.1

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AUX102 Inputs and Outputs TABLE 2.

NUMBER OF INPUTS AND OUTPUTS ON THE AUX102

Description

Value

Number of Inputs

4

Number of Outputs

8

2.3.2

AUX102 Inputs An AUX102 input can be associated with a fault code. When the input is active, the fault is active. When the input is inactive, the fault is inactive, though the fault might have to be reset. Alternatively, some AUX102 inputs can be assigned specific input functions instead of a fault code. These functions have a variety of effects and vary by controller.

2.3.3

AUX102 Outputs Each AUX102 output is associated with a fault code. When the fault is active, the output is active. When the fault is inactive, the output is inactive.

2.4

Numbering of AUX102 Inputs and Outputs The AUX102 requires the AUX101. As a result, many operator panels and software programs start numbering AUX102 inputs and outputs at 9 instead of 1. For example, AUX102 output 1 may be referred to as AUX102 output 9, output 9, or even AUX101 output 9. All of these expressions refer to the same output.

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Characteristics of the AUX 101 and AUX 102 with Various Controllers You should be familiar with the characteristics of the AUX 101 and AUX 102 before you attempt to install them. The characteristics vary by controller.

3.1

Characteristics of the AUX 101 and AUX 102 with the PCC 1301, PCC 1302, and PowerCommand 1.x

3.1.1

Maxim um Numb er of AUX 101/102 for the PCC 1301, PCC 1302, and PowerCommand 1.x TABLE 3.

MAXIMUM NUMBER OF AUX 101/102 FOR THE PCC 1301, PCC 1302, AND POWERCOMMAND 1.X

Description

Value

Maximum Number of AUX 101

2


2

3.1.2

Required Part Numbers for Operator Panel Software to Suppor t the AUX 101

TABLE 4.

REQUIRED PART NUMBERS FOR OPERATOR PANEL SOFTWARE TO SUPPORT THE AUX 101

Software

Part Number

Operator panel software

326-6652 (limited) 326-6333

3.1.2.1 How to Determine the Part Number of the Operator Panel Software Use the History/About menus to determine the part number of the operator panel software. The part number of the operator panel software is also displayed when the message "Establishing communication with control" is displayed during startup.

3.1.2.2 Configuration Limit ations in Operator Panel Software Version 0326-6652 If the operator panel is running software part number 0326-6652, the operator panel can only configure the event type and display text for AUX 101 inputs 1-8 that are active-low. The operator panel cannot configure AUX 101 outputs, an AUX 102, or other types of AUX 101 inputs 1-8. Other versions of the operator panel allow for complete configuration of both the AUX 101 and AUX 102.

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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers

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NOTICE The software uses Active High and Active Low, but the hardware connection is really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. Make sure the hardware is connected appropriately.

3.1.2.3 How to Upgrade Software on the AUX 101 1. Go to the InCal web site to get the latest software for the controller, operator panel, and AUX 101. 2. Upgrade the software on the controller and on the operator panel, based on the instructions provided with them. 3. Use InPower to upgrade the software in the AUX 101.

3.1.3

Possible Functi ons of AUX 101 Inputs for PCC 1301, PCC 1302, and PowerCommand 1.x NOTICE The software uses Active High and Active Low, but the hardware connection is really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. Make sure the hardware is connected appropriately.

TABLE 5.

POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR PCC 1301, PCC 1302, AND POWERCOMMAND 1.X

Input

Possible Functions

1

Switch (active-high or active-low), voltage bias

2

Switch (active-high or active-low), speed bias

3-6

Switch (active-high or active-low), exhaust temperature sender, ambient temperature sender, fuel level sender, alternator temperature sender, intake manifold sender, oil temperature sender

7-8

Switch (active-high or active-low)

3.1.3.1 Default Functio ns of AUX 101 Inpu ts for PCC 1301, PCC 1302, and PowerCommand 1.x All AUX 101 inputs are disabled.

3.1.3.2 PCC 1301 Fault Codes Generated by AUX 101 Switch Inputs TABLE 6.

PCC 1301 FAULT CODES GENERATED BY AUX 101 SWITCH INPUTS

Input

1

8

Fault Code Event

Warning

Shutdown

163

226

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2

164

227

85

3

165

228

86

4

166

229

87

5

167

230

88

6

168

231

89

7

169

232

90

8

170

233

91

3.1.4

Default Functi ons of A UX 101 Outputs with the PCC 1301, PCC 1302, and PowerCommand 1.x

TABLE 7.

DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE PCC 1301, PCC 1302, AND POWERCOMMAND 1.X

Output

Default Function

1

Low oil pressure

2

High engine temperature

3

Charger AC failure

4

Battery (low, weak, or high)

5

Overspeed

6

Fail to start

7

Not in auto

8

Run

3.1.4.1 About AUX 101 Output 4 AUX 101 output 4 can be associated with up to three fault codes. If any of the fault codes are active, the output is active. If none of the fault codes are active, the output is inactive.

3.1.5

Possible Functi ons of AUX 102 Inputs for PCC 1301, PCC 1302, and PowerCommand 1.x NOTICE The software uses Active High and Active Low, but the hardware connection is really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. Make sure the hardware is connected appropriately.

TABLE 8.

POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR PCC 1301, PCC 1302, AND POWERCOMMAND 1.X

Input

Possible Functions

9-12

Active-low switch

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3.1.5.1 Default Functio ns of AUX 102 Inpu ts for PCC 1301, PCC 1302, and PowerCommand 1.x All AUX 102 inputs are disabled.

3.1.5.2 PCC 1301 Fault Codes Generated by AUX 102 Switch Inputs TABLE 9.

PCC 1301 FAULT CODES GENERATED BY AUX 102 SWITCH INPUTS

Input

Fault Code Event

Warning

Shutdown

9

171

234

92

10

172

235

93

11

173

236

94

12

174

237

95

3.1.6

Default Functi ons of A UX 102 Outputs with the PCC 1301, PCC 1302, and PowerCommand 1.x

TABLE 10. DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE PCC 1301, PCC 1302, AND POWERCOMMAND 1.X Output

Default Function

9

Pre-low oil pressure

10

Pre-high engine temperature

11

Low coolant level*

12

Low fuel level*

13

Low coolant temperature

14

Common alarm

15

Not defined

16

Not defined

* - These are the default settings if the PCC 1301 Customer Inputs are defined as Low Coolant Level or Low Fuel Level. By default, the PCC 1301 Customer Inputs are defined in this manner.

3.2

Characteristics of the AUX 101 and AUX 102 with the PCC 2100

3.2.1

Maximu m Number of AUX 101/102 for the PCC 2100 TABLE 11.

Description

MAXIMUM NUMBER OF AUX 101/102 FOR THE PCC2100 Value


2*


2*

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* - The PCC 2100 does not support any additional inputs on the second AUX 101 or second AUX 102. It only supports the additional outputs.

3.2.2

Possible Functi ons of AUX 101 Inputs for PCC 2100 NOTICE The software uses Active High and Active Low, but the hardware connection is really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. Make sure the hardware is connected appropriately.

TABLE 12.

POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR PCC 2100

Input

Possible Functions

1

Switch (active-high or active-low), voltage bias

2

Switch (active-high or active-low), speed bias

3-8

Switch (active-high or active-low)

3.2.2.1 Default Funct ion s of AUX 101 Inpu ts fo r PCC 2100 All AUX 101 inputs are disabled.

3.2.3

Default Functi ons of A UX 101 Outputs with the PCC 2100 TABLE 13.

DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE PCC 2100

Output

Default Function

1

Low oil pressure

2


3

Not defined

4

Battery (low, weak, or high)

5

Overspeed

6

Fail to start

7

Not in auto

8

Run

3.2.3.1 About AUX 101 Output 4 AUX 101 output 4 can be associated with up to three fault codes. If any of the fault codes are active, the output is active. If none of the fault codes are active, the output is inactive.

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Possible Functi ons of AUX 102 Inputs for PCC 2100 NOTICE The software uses Active High and Active Low, but the hardware connection is really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. Make sure the hardware is connected appropriately.

TABLE 14.

POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR PCC 2100

Input

Possible Functions

9-12

Active-low switch

3.2.4.1 Default Funct ion s of AUX 102 Inpu ts fo r PCC 2100 All AUX 102 inputs are disabled.

3.2.5

Default Functi ons of A UX 102 Outputs with the PCC 2100 TABLE 15.

DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE PCC 2100

Output

Default Function

9


10


11

Not defined

12

Not defined

13

Low engine temperature

14

Not defined

15

Not defined

16

Not defined

3.3

Characteristics of the AUX101 and AUX102 with the PowerCommand 2.x and 3.x

3.3.1

Maximu m Number of AUX101/102 for the PowerCommand 2.x and 3.x

TABLE 16. MAXIMUM NUMBER OF AUX101/102 FOR THE POWERCOMMAND 2.X AND 3.X Description

Value

Maximum Number of AUX101

2

Maximum Number of AUX102

2

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Required Part Numbers to Support the AUX101 for the PowerCommand 2.x

TABLE 17. REQUIRED PART NUMBERS TO SUPPORT THE AUX101 FOR THE POWERCOMMAND 2.X Component

Part Number

PCC2300 base board

A026N036

NOTICE PCC2300 base board 0327-1636 does not support the AUX101.

3.3.3

Possible Functions of AUX101 Inputs for PowerCommand 2.x and 3.x

TABLE 18. POSSIBLE FUNCTIONS OF AUX101 INPUTS FOR POWERCOMMAND 2.X AND 3.X Input

Possible Functions

1-2

Switch (active-open or active-closed)

3-6

Switch (active-open or active-closed), additional functions for configurable inputs, additional functions for configurable analog inputs

7-8

Switch (active-open or active-closed)

3.3.3.1 Default Functi ons o f AUX101 Inpu ts for PowerCommand 2.x and 3.x All AUX101 inputs are disabled.

3.3.3.2 Addition al Functions of Configurable Inputs on the PowerCommand 2.x Each configurable input can be mapped to one of these functions, instead of their default function. TABLE 19. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 2.X Function Low Fuel in Day Tank Switch Low Coolant Switch #2 High Alt Temperature Switch Ground Fault Switch Exercise Switch Battle Short Switch Battery Charger Failed Switch

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Related Settings Low Fuel in Day Tank Time None High Alternator Temperature Shutdown Threshold (Aux101), High Alternator Temperature 1 Time (Aux101) Ground Fault Current Delay, Ground Fault Current Threshold Percent Genset Exercise Time Battle Short Enable None

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Low Engine Temperature Switch

5-2015

None

Speed Droop Enable Switch

Speed Droop Percentage

Voltage Droop Enable Switch

Voltage Droop Percentage

NOTICE Currently, Speed Droop Enable Switch and Voltage Droop Enable Switch are not available, but they appear in the Operator Panel.

You can only map one configurable input to each of these functions. For example, there cannot be two Battle Short Switches. You can also set up a configurable input to do nothing at all .

3.3.3.3 Addition al Functions of Configurable Inputs on the PowerCommand 3.x Each configurable input can be mapped to one of these functions, instead of their default function. TABLE 20. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 3.X Function Manual Run Switch Low Fuel in Day Tank Switch Low Coolant Switch #2 High Alt Temperature Switch Ground Fault Switch PTC Mode Switch

Related Settings None Low Fuel in Day Tank Time None High Alternator Temperature Shutdown Threshold (Aux101), High Alternator Temperature 1 Time (Aux101) Ground Fault Current Delay, Ground Fault Current Threshold Percent See PTC settings.

Masterless Load Demand Enable Switch

Not available

Predictive Load Enable Switch

Not available

Ramp Load/Unload Switch

Exercise Switch Battle Short Switch

Load Govern kVAR Ramp Load Time, Load Govern kVAR Ramp Unload Time, Load Govern kW Ramp Load Time, Load Govern kW Ramp Unload Time, Load Share Ramp Load Time, Load Share Ramp Unload Time Genset Exercise Time Battle Short Enable

Battery Charger Failed Switch

None

Low Engine Temperature Switch

None

Speed Droop Enable Switch

Speed Droop Percentage

Voltage Droop Enable Switch

Voltage Droop Percentage

NOTICE Masterless Load Demand Enable Switch and Predictive Load Enable Switch are not available yet.

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You can only map one configurable input to each of these functions. For example, there cannot be two Battle Short Switches. You can also set up a configurable input to do nothing at all.

3.3.3.4 Addition al Functions of Configurable Analog Inputs on the PowerCommand 2.x and 3.x Each configurable input can be mapped to one of these functions, instead of their default function . TABLE 21.

ADDITIONAL FUNCTIONS OF CONFIGURABL E ANALOG INPUTS ON THE POWERCOMMAND 2.X AND 3.X Function

Related Settings

Oil Temperature

High Oil Temperature Threshold (Aux101), High Oil Temperature Time (Aux101), Aux 101 Oil/Ambient/Intake Manifold Temp Input Scaling Table, Aux101 Oil Temp OOR Check Enable, Aux101 Oil/Ambient/Intake Manifold Temp OOR High Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Low Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Time

Exhaust Stack Temperature 1

Aux 101 Exhaust Stack Temp Input Scaling Table, High Exhaust Stack Temperature 1 Threshold (Aux101), High Exhaust Stack Temperature 1 Time (Aux101), Aux101 Exhaust Stack Temp 1 OOR Check Enable, Aux101 Exhaust Stack Temp OOR High Limit, Aux101 Exhaust Stack Temp OOR Low Limit, Aux101 Exhaust Stack Temp OOR Time

Exhaust Stack Temperature 2

Aux 101 Exhaust Stack Temp Input Scaling Table, High Exhaust Stack Temperature 2 Threshold (Aux101), High Exhaust Stack Temperature 2 Time (Aux101), Aux101 Exhaust Stack Temp 2 OOR Check Enable, Aux101 Exhaust Stack Temp OOR High Limit, Aux101 Exhaust Stack Temp OOR Low Limit, Aux101 Exhaust Stack Temp OOR Time

Ambient Temperature

Ambient Temp Fault Delay, Ambient Temp Fault Level, Ambient Temp Fault Threshold, Aux 101 Oil/Ambient/Intake Manifold Temp Input Scaling Table, Aux101 Ambient Temp OOR Check Enable, Aux101 Oil/Ambient/Intake Manifold Temp OOR High Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Low Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Time

Fuel Level

Fuel Level 100 Percent Resistance (Aux101), Fuel Level Zero Percent Resistance (Aux101), High Fuel Level Threshold (Aux101), High Fuel Level Time (Aux101), Low Fuel Level Threshold (Aux101), Low Fuel Level Time (Aux101), Low Fuel Set/Clear Time, Very Low Fuel Level Threshold (Aux101), Very Low Fuel Level Time (Aux101), Aux101 Fuel Level OOR Check Enable, Aux101 Fuel Level OOR High Limit, Aux101 Fuel Level OOR Low Limit, Aux101 Fuel Level OOR Time

Alternator Temperature 1

High Alternator Temperature 1 Threshold (Aux101), High Alternator Temperature 1 Time (Aux101), Aux101 Alternator Temperature OOR Check Enable, Aux101 Alternator Temperature OOR High Limit, Aux101 Alternator Temperature OOR Low Limit, Aux101 Alternator Temperature OOR Time

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Intake Manifold Temperature 1

High Intake Manifold Temperature 1 Threshold (Aux101), High Intake Temperature 1 Time (Aux101), Aux 101 Oil/Ambient/Intake Manifold Temp Input Scaling Table, Aux101 Intake Manifold Temp OOR Check Enable, Aux101 Oil/Ambient/Intake Manifold Temp OOR High Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Low Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR Time

Drive End Bearing Temperature

High Drive End Bearing Temperature Threshold (Aux101), High Drive End Bearing Temperature Time (Aux101), Aux101 Drive End Bearing Temperature OOR Check Enable, Aux101 Drive/Non-Drive End Bearing Temp OOR High Limit, Aux101 Drive/Non-Drive End Bearing Temp OOR Low Limit, Aux101 Drive/Non-Drive End Bearing Temperature OOR Time

Non-Drive End Bearing Temperature

High Non-Drive End Bearing Temperature Threshold (Aux101), High Non-Drive End Bearing Temperature Time (Aux101), Aux101 Non-Drive End Bearing Temperature OOR Check Enable, Aux101 Drive/Non-Drive End Bearing Temp OOR High Limit, Aux101 Drive/Non-Drive End Bearing Temp OOR Low Limit, Aux101 Drive/NonDrive End Bearing Temperature OOR Time

You can only map one configurable analog input to each of these functions. For example, there cannot be two Fuel Level inputs. You can also set up a configurable analog input to do nothing at all.

3.3.3.5 PowerCommand 2.x and 3.x Fault Codes Generated by AUX101 Switch Inputs TABLE 22. POWERCOMMAND 2.X AND 3.X FAULT CODES GENERATED BY AUX101 SWITCH INPUTS Input

16

Fault Code Device 0

Device 1

1

2619

2882

2

2621

2883

3

2622

2884

4

2623

2885

5

2624

2886

6

2625

2887

7

2626

2888

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2627

2889

Default Functions of AUX101 Outputs with the PowerCommand 2.x and 3.x

TABLE 23. DEFAULT FUNCTIONS OF AUX101 OUTPUTS WITH THE POWERCOMMAND 2.X AND 3.X Output

Default Function

1

Low oil pressure

2


3

Charger AC failure

4

Low battery voltage

5

Overspeed

6

Fail to start

7

Not in auto

8

Ready to load

3.3.5

Possible Functions of AUX102 Inputs for PowerCommand 2.x and 3.x

TABLE 24. POSSIBLE FUNCTIONS OF AUX102 INPUTS FOR POWERCOMMAND 2.X AND 3.X Input

Possible Functions

9-12

Switch (active-open or active-closed), additional functions for configurable inputs

3.3.5.1 Default Functi ons o f AUX102 Inpu ts for PowerCommand 2.x and 3.x All AUX102 inputs are disabled.

3.3.5.2 PowerCommand 2.x and 3.x Fault Codes Generated by AUX102 Switch Inputs TABLE 25. POWERCOMMAND 2.X AND 3.X FAULT CODES GENERATED BY AUX102 SWITCH INPUTS Input

Fault Code Device 0

Device 1

9

2628

2891

10

2629

2892

11

2631

2893

12

2632

2894

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Default Functions of AUX102 Outputs with the PowerCommand 2.x and 3.x

TABLE 26. DEFAULT FUNCTIONS OF AUX102 OUTPUTS WITH THE POWERCOMAND 2.X AND 3.X

18

Output

Default Function

9


10


11

Low coolant level

12

Low fuel in day tank

13

Low coolant temperature

14

Common alarm

15

High battery voltage

16

Weak battery

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Hardware

4.1

AUX101 Board

FIGURE 1.

4.1.1

AUX101 BOARD

AUX101 S1 The S1 button can be used to change the AUX101 device number.

4.1.2

AUX101 Device Number Indicator The AUX101 device number indicator displays the device number of this particular AUX101 in a PCCNet network. If there is only one AUX101 in the PCCNet network, the device number must be zero (0). If there is more than one AUX101 in the PCCNet network, the device number of the first AUX101 must be zero (0). The device number of any other AUX101 cannot be zero, and it must be unique in the PCCNet network.

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4.1.2.1 Changin g th e AUX101 Device Number 1. Press and hold S1 for at least five seconds. On the AUX101 device number indicator, a small dot should appear next to the current device number. 2. Press and release S1 until the desired number is displayed. 3. Wait five seconds. After five seconds of inactivity, the new device number is set, and the small dot should disappear. 4. Disconnect and reconnect J14 to cycle power to the AUX101.

4.1.3

AUX101 Indicators TABLE 27.

In di cat or

Des cr ipt io n

DS1

This is on if the AUX101 is connected to a PCCNet network and is operating normally.

DS2

This is on if the AUX101 is not connected to the PCCNet network.

DS3

This is on if AUX101 output 1 is active.

DS4


DS5


DS6


DS7


DS8


DS9


DS10


4.1.4

AUX101 Connectors TABLE 28.

Co nn ec to r

20

AUX101 INDICATORS

AUX101 CONNECTORS

Des cr ip ti on

J1

Connection to controller

J2

AUX101 outputs 1-4

J3

AUX101 outputs 5-6

J4

AUX101 outputs 7-8

J5

Connection to AUX102

J10

Voltage sources, current sources

J11

AUX101 inputs 1-8

J14

Power supply

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4.1.4.1 AUX101 J1

Pin

Description

J1-1

Output power B-

J1-2

Output power B+

J1-3

PCCNet A

J1-4

PCCNet B

J1-5

System wakeup

FIGURE 2.

AUX101 J1

TABLE 29.

AUX101 J1

FIGURE 3.

AUX101 J2

TABLE 30.

AUX101 J2

4.1.4.2 AUX101 J2

Pin

Description J2-1

AUX101 output 1, normally-open contact

J2-2

AUX101 output 1, common contact

J2-3

AUX101 output 1, normally-closed contact

J2-4


J2-5


J2-6


J2-7


J2-8


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Pin

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Description J2-9


J2-10


J2-11


J2-12


4.1.4.2.1 AUX101 Output 1-8 Specificati ons TABLE 31.

AUX101 OUTPUT 1-8 SPECIFICATIONS

Description

Value

Output Type

Non-latching relay

Maximum Output Voltage

250 VAC or 30 VDC

Maximum Output Current from Normally-open Contact

3A

Maximum Output Current from Normally-closed Contact

3A

4.1.4.3 AUX101 J3

22

FIGURE 4.

AUX101 J3

TABLE 32.

AUX101 J3

Pin

Description

J3-1


J3-2


J3-3


J3-4


J3-5


J3-6


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Description

Value

Output Type

Non-latching relay

Maximum Output Voltage

250 VAC or 30 VDC


3A


3A

4.1.4.4 AUX101 J4

FIGURE 5.

AUX101 J4

TABLE 34.

AUX101 J4

Pin

Description

J4-1


J4-2


J4-3


J4-4


J4-5


J4-6




Description Output Type Maximum Output Voltage

Value Non-latching relay 250 VAC or 30 VDC


3A


3A

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4.1.4.5 AUX101 J5 If the AUX101 is connected to an AUX102, this is connected to J6 on the AUX102.

FIGURE 6.

AUX101 J5

There is no pin description for AUX101 J5.

4.1.4.6 AUX101 J10

Pin

24

FIGURE 7.

AUX101 J10

TABLE 36.

AUX101 J10

Description

J10-1

CAN H

J10-2

CAN L

J10-3

Current source 1

J10-4

Current source 2

J10-5

Current source 3

J10-6

Current source 4

J10-7

Voltage source 1

J10-8

Voltage source 2

J10-9

Ground for current source or voltage source

J10-10


J10-11


J10-12


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4.1.4.6.1 AUX101 Current Sour ce Specif ications TABLE 37.

AUX101 CURRENT SOURCE SPECIFICATIONS

Description

Value

Maximum Output Current

20 mA

4.1.4.6.2 AUX101 Voltage Source Specifi cations TABLE 38.

AUX101 VOLTAGE SOURCE SPECIFICATIONS

Description

Value

Output Voltage

5 VDC

Maximum Output Current

20 mA

4.1.4.7 AUX101 J11

Pin

FIGURE 8.

AUX101 J11

TABLE 39.

AUX101 J11

Description J11-1

AUX101 input 1, reference input

J11-2

AUX101 input 1, switch input

J11-3


J11-4


J11-5


J11-6


J11-7


J11-8


J11-9


J11-10


J11-11


J11-12


J11-13


J11-14


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Pin

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Description J11-15


J11-16


4.1.4.7.1 AUX101 Input 1-2 Specif ications TABLE 40.

AUX101 INPUT 1-2 SPECIFICATIONS

Description

Value

Input Type

Discrete or analog

Maximum Input Voltage

24 VDC

Differential Voltage Range

-5~5 VDC



Description

Value

Input Type

Discrete or analog


24 VDC


0~5 VDC



Description

Value

Input Type

Discrete or analog


40 VDC


0~38 VDC

4.1.4.8 AUX101 J14

Pin

26

FIGURE 9.

AUX101 J14

TABLE 43.

AUX101 J14

Description

J14-1

Input power B+

J14-2

Input power B-

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4.1.4.8.1 AUX101 and AUX102 Power Specific ations TABLE 44.

AUX101 AND AUX102 POWER SPECIFICATIONS

Description

Value

Input Voltage

5-40 VDC

Operating Voltage

12 VDC or 24 VDC

Current Consumption

4.2

900 mA (12 VDC) 450 mA (24 VDC)

AUX102 Board

FIGURE 10.

4.2.1

AUX102 BOARD

AUX102 Indicators TABLE 45.

Indicator

AUX102 INDICATORS

Description

DS1


DS2


DS3


DS4


DS5


DS6


DS7


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DS8

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AUX102 Connectors TABLE 46.

Connector

AUX102 CONNECTORS

Description

J1

AUX102 outputs 1-8, normally-open contacts

J2

AUX102 outputs 1-8, common contacts

J3

AUX102 outputs 1-8, normally-closed contacts

J4

AUX102 inputs 9-12

J5

Chassis ground

J6

Connection to AUX101

4.2.2.1 AUX102 J1

Pin

28

FIGURE 11.

AUX102 J1

TABLE 47.

AUX102 J1

Description J1-1


J1-2


J1-3


J1-4


J1-5


J1-6


J1-7


J1-8


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4.2.2.2 AUX102 J2

FIGURE 12.

AUX102 J2

TABLE 48.

AUX102 J2

Pin

Description

J2-1


J2-2


J2-3


J2-4


J2-5


J2-6


J2-7


J2-8


4.2.2.3 AUX102 J3

Pin

FIGURE 13.

AUX102 J3

TABLE 49.

AUX102 J3

Description J3-1


J3-2


J3-3


J3-4


J3-5


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Pin

5-2015

Description J3-6


J3-7


J3-8


4.2.2.4 AUX102 J4

FIGURE 14.

AUX102 J4

TABLE 50.

AUX102 J4

Pin

Description

J4-1


J4-2


J4-3


J4-4


J4-5


J4-6


J4-7


J4-8


4.2.2.5 AUX102 J5 J5 is connected to a good earth ground.

4.2.2.6 AUX102 J6 This is connected to J5 on the AUX101.

FIGURE 15.

30

AUX102 J6

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4.3

How to Install the AUX 101/102 Hardware WARNING Incorrect installation. Incorrect installation, service, or parts replacement can result in severe personal injury, death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical component installations.

WARNING AC vo lt ages . AC vo lt ages and cu rr ent s pr esen t an elec tr ic al sh oc k hazar d. Inc or rec t in st all ati on , ser vi ce, or parts replacement can cause severe personal injury or death. Service personnel must be trained and experienced to perform electrical and mechanical component installations

.

WARNING If present, always disconnect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the generator set.

WARNING Ac ci den tal st art in g of th e gen erat or set wh il e wo rk in g on it can cau se sev ere per so nal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative [-] first). Make certain t he battery area has been w ell-ventilated before s ervicing the battery--Wear goggles--Stop the generator set and disconnect the charger before disconnecting battery cables. Ar ci ng can ig ni te exp lo si ve hy dr og en gas gi ven of f by bat ter ies , cau si ng sev ere per so nal in ju ry . Ar ci ng can oc cu r wh en a cab le is rem ov ed or re-at tac hed , or wh en th e neg ati ve (-) bat ter y cab le is connected and a tool used to connect or disconnect the positive (+) battery cable touches the frame or other grounded metal part of the generator set. Always remove the negative (-) cable first, and reconnect it last. Make certain hydrogen from the battery, engine fuel, and other explosive fumes are fully dissipated. This is especially important if the battery has been connected to a battery charger.

WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals can ignite battery gases. Ventilate the area before working on batteries. Wear safety glasses and do not smoke. Always stop the generator set before disconnecting the battery. Always disconnect the negative (–) cable first and reconnect it last.

NOTICE Mounting hardware for the AUX 101 and AUX 102 are not included. These instructions include suggested hardware sizes.

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NOTICE 1. Make sure the generator set is shut down and disabled. a. The controller is in the Off mode. b. The generator set Run/Off/Auto switch is in the Off position, and the generator set is cool to the touch. c. The emergency stop button has been pressed for at least thirty seconds. d. Any power supplies (for example, heaters or pumps) are isolated. The battery charger and starting battery should be isolated later. e. The battery charger (if equipped) is turned off and disconnected. f. The negative (-) cable from the battery is disconnected to prevent accidental starting. g. A "Maintenance in Progress" sign is displayed, and the appropriate lockout/tagout procedures are followed. 2. Select a suitable location, and mount the AUX 101 using M4 screws and associated hardware. 3. If the AUX 102 is included, use M4 screws and associated hardware to mount the AUX 102 near the AUX 101, and plug the AUX 102 J6 connector into the AUX 101 J5 connector. Use a screw and lock washer to ground the AUX 102 J5 ring terminal. 4. Install any new sensors or switches that you plan to connect to the AUX 101 or AUX 102. 5. Select appropriate wire, and connect wiring from the controller TB1 connector to the enclosed 5-pin connector. Plug the connector into the AUX 101 J1 connector. 6. Connect any system equipment to AUX 101 outputs and, if installed, AUX 102 outputs. 7. Connect any system equipment to AUX 101 inputs and, if installed, AUX 102 inputs. 8. Connect any system equipment to AUX 101 ground, voltage sources, and current sources. 9. Select the appropriate wire for power connections, and install wiring on the enclosed 2-pin connector. Connect the wiring to the power source, and plug the connector into the AUX 101 J14 connector. 10. Reconnect the generator set. a. Connect the negative (-) cable to the battery. b. Reconnect the battery charger (if equipped). c. Reconnect any other power supplies. d. Unpress the emergency stop button, and reset the fault in the controller. e. Place the Run/Off/Auto switch in the desired position. f. Set the controller to the desired mode. 11. Verify that the AUX 101 LED DSL1 is green and that all devices are powered.

4.3.1

Wiring Diagrams Available See Wiring Diagrams for wiring diagrams you can use in these procedures.

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4.3.2

4. Hardware

Guidelines for Mountin g the AUX 101/102 The AUX 101 and AUX 102 are suitable for mounting on a non-engine panel inside an enclosure. They should not be mounted directly on the engine. To prevent the AUX 101 and AUX 102 from being exposed to conditions beyond its specifications, care should be taken not to mount it close to the engine exhaust pipes. Avoid mounting the AUX 101 and AUX 102 in a manner that would expose them to direct sunlight, rain, or snow. Choose a clean, vibration-free mounting surface. Avoid locations that are hot, damp, or dusty or that are close to sources of electromagnetic interference (EMI).

4.3.2.1 AUX 101 and A UX 102 Envir onm ental Specific ations TABLE 51.

AUX 101 AND AUX 102 ENVIRONMENTAL SPECIFICATIONS

Description

Value

Storage Temperature

-40~85 C (-40~185 F)

Operating Temperature

-40~60 C (-40~140 F)

Maximum Humidity

95%, non-condensing

4.3.2.2 AUX 101 and A UX 102 Footp rint

FIGURE 16. AUX 101 AND AUX 102 FOOTPRINT

NOTICE The outside dimensions do not i nclude necessary clearance for wire connections.

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Pin Connectio ns for AUX101 Inputs 1-8 TABLE 52.

4.3.4

Input

Pins

1

J11-1, J11-2

2

J11-3, J11-4

3

J11-5, J11-6

4

J11-7, J11-8

5

J11-9, J11-10

6

J11-11, J11-12

7

J11-13, J11-14

8

J11-15, J11-16

Pin Connectio ns for AUX102 Inputs 9-12 TABLE 53.

4.3.5

Pins

9

J4-1, J4-2

10

J4-3, J4-4

11

J4-5, J4-6

12

J4-7, J4-8

Pin Connectio ns for AUX101 Outputs 1-8 PIN CONNECTIONS FOR AUX101 OUTPUTS 1-8

Output

Pins

1

J2-1, J2-2, J2-3

2

J2-4, J2-5, J2-6

3

J2-7, J2-8, J2-9

4

J2-10, J2-11, J2-12

5

J3-1, J3-2, J3-3

6

J3-4, J3-5, J3-6

7

J4-1, J4-2, J4-3

8

J4-4, J4-5, J4-6

Pin Connectio ns for AUX102 Outputs 9-16 TABLE 55. Output

34

PIN CONNECTIONS FOR AUX102 INPUTS 9-12

Input

TABLE 54.

4.3.6

PIN CONNECTIONS FOR AUX101 INPUTS 1-8

PIN CONNECTIONS FOR AUX102 OUTPUTS 9-16 Pins

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4. Hardware

9

J1-1, J2-1, J3-1

10

J1-2, J2-2, J3-2

11

J1-3, J2-3, J3-3

12

J1-4, J2-4, J3-4

13

J1-5, J2-5, J3-5

14

J1-6, J2-6, J3-6

15

J1-7, J2-7, J3-7

16

J1-8, J2-8, J3-8

Example of a Connection

FIGURE 17. EXAMPLE OF A CONNECTION

NOTICE Input pin is grounded.

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4.3.8

5-2015

RTDs - About Four-wire Connections When measuring the resistance of a RTD (resistance temperature detector or resistive thermal device) located a significant distance away, the resistance in the wire can reduce the accuracy of the measurement. In this case, a four-wire connection can provide a more accurate measurement.

FIGURE 18.

FOUR-WIRE CONNECTION

In a four-wire connection, one set of wires provides a fixed current to the component, and a second set of wires measures the voltage drop across the component. The resistance is calculated by dividing the voltage drop by the fixed current. While there is resistance in the wires that measure the voltage drop, the voltmeter produces much less current than the current source, so the voltage drop due to resistance in the voltmeter wires is significantly smaller.

4.3.8.1 How to Convert a Four-wire Connection Into a Two-wire Connection If you want to make a two-wire connection to a device that provides a four-wire connection, connect a jumper between each pair of pins.

FIGURE 19. 36

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4. Hardware

In this type of connection, the voltmeter measures the voltage drop across the component and the voltage drop due to resistance in the wire. As a result, the longer the wires, the more inaccurate the measurement. If you want to make a three-wire connection, connect a jumper between one pair of pins. The accuracy of a three-wire connection is better than that of a two-wire connection but worse than that of a four-wire connection.

4.3.9

Example of a Voltage Bias Connection with One Power Supply

FIGURE 20.

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EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH ONE POWER SUPPLY

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4.3.10 Example of a Voltage Bias Connectio n w ith Two Power Supplies

FIGURE 21.

EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH TWO POWER SUPPLIES

4.3.11 Example of a Speed Bias Connection

FIGURE 22.

38

EXAMPLE OF A SPEED BIAS CONNECTION

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4.4

4. Hardware

Repairing Circuit Boards WARNING At tem pt in g to rep air ci rc ui t bo ard s can lead to equ ip men t dam age, per so nal in ju ry , or deat h. Replace faulty circuit boards. Do not try to r epair f aulty circuit boards.

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Config on figur ura ation tion of the AUX AUX 101 and AUX AUX 102 with Various Controllers

5.1

Tools to Configure Configure a PCC 1301 or Powe PowerC rComma ommand nd 1.x AUX 101/102 You You must must use use one one of thes these e tool tools s to conf config igur ure e the the AUX AUX 101 101 and and AUX AUX 102 102 sett settin ings gs in the the controller. • Operat Operator or panel panel • InPowe InPowerr servi service ce tool tool

NOTICE For some settings, InPower InPower has more options than the operator panel. panel. If you use InPower to select an option that is not available in the operator panel, the operator panel panel di splays " N/A". N/A".

5.1.1

About the I/O Module Module Menus Use the I/O Module menus to configure the inputs and outputs on the AUX 101 and, if installed, AUX 102. The I/O Module menu consist of three submenus. • Inputs Inputs:: Select Select the functi function on of each input, input, and config configure ure any inputs inputs that are active active-hi -high gh switches or active-low switches. Once an input is configured, you can use this submenu to look at the current value of the input. • Outputs: Outputs: Configur Configure e each output. output. • Senders: Senders: Configure Configure any inputs inputs that that are senders. senders. The Senders submenu does not appear unless one or more inputs are senders.

NOTICE The software software uses Active High and Active Low, but the hardware hardware connection is really really Ac ti ve Open and Ac ti ve Clo sed , res pec ti vel y. Thi s sec ti on us es Ac ti ve Hig h and Ac ti ve Low to be consistent with the software. software. Make Make sure the hardware hardware is connected connected appropriately.

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5. Configuration of the AUX 101 and AUX 102 with Various Controllers

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5.1. 5.1.1. 1.1 1 How to Find t he I/O I/O Module Menu Menu in the PCC PCC 1301 1301 Operator Operator Panel

FIGURE FIGURE 23. HOW TO FIND FIND THE I/O MODULE MODULE MENU MENU IN THE PCC 1301 1301 OPERATOR OPERATOR PANEL

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NOTICE If the password is not entered or is entered incorrectly, you can view the menus, but the CONFIG and ADJUST buttons are blacked out. You will not be able to change any values.

5.1.1.2 How to Configu re a Switch on a PCC 1301, PCC 1302, or PowerCommand 1.x 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Inputs submenu. 3. Press the selection buttons to find the input that will be a switch. 4. Press the CONFIG button to configure the input. The operator panel should display a list of available functions for the input. 5. Press the appropriate button to set the function of the input to "Switch". The operator panel should display the current settings of the switch. 6. Press the ADJUST button to configure the switch. 7. Enter a brief description of the event (up to 32 characters) and the event type (Event, Warning, or Shutdown). 8. Press the SAVE button to save your changes. 9. Select the event logic (Active Low or Active High). 10. Press the SAVE button to save your changes.


5.1.1.3 How to Configu re an Ac tive-low Switch on a PCC 1301, PCC 1302, or PowerCommand 1.1 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Inputs submenu. 3. Press the selection buttons to find the input that will be an active-low switch. 4. Press the CONFIG button to configure the input. The operator panel should display the current settings of the active-low switch. 5. Press the ADJUST button to configure the active-low switch. 6. Enter a brief description of the event (up to 32 characters) and the event type (Event, Warning, or Shutdown). 7. Press the SAVE button to save your changes.

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5.1.1.4 How to Configu re a Voltage Bias on a PCC 1301, PCC 1302, or PowerCommand 1.x 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Inputs submenu. 3. Press the selection buttons to find the input that will be a voltage bias. 4. Press the CONFIG button to configure the input. The operator panel should display the available functions for the input. If "Voltage Bias" is not available, select an input that can be a voltage bias. 5. Press the appropriate button to set the function of the input to "Voltage Bias". The operator panel should display the current settings of the voltage bias. 6. Press the ADJUST button to configure the voltage bias. 7. Press the (+) and (-) buttons to set the voltage bias scale. The scale sets the range of the voltage bias. For example, if the scale is 3 V, the voltage bias is +/- 3 V. 8. Press the SAVE button to save your changes.

5.1.1.5 How to Configu re a Speed Bias o n a PCC 1301, PCC 1302, or PowerCommand 1.x 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Inputs submenu. 3. Press the selection buttons to find the input that will be a speed bias. 4. Press the CONFIG button to configure the input. The operator panel should display the available functions for the input. If "Speed Bias" is not available, select an input that can be a speed bias. 5. Press the appropriate button to set the function of the input to "Speed Bias". The operator panel should display the current settings of the speed bias. 6. Press the ADJUST button to configure the speed bias. 7. Press the (+) and (-) buttons to set the speed bias scale. The scale sets the range of the speed bias. For example, if the scale is 120 rpm, the voltage bias is +/- 120 rpm. 8. Press the SAVE button to save your changes.

5.1.1.6 How to Configu re a Sender on a PCC 1301, PCC 1302, or PowerCommand 1.x 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Inputs submenu. 3. Press the selection buttons to find the input that will be a sender. 44

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4. Press the CONFIG button to configure the input. The operator panel should display the available functions for the input. If "Sender" is not available, select an input that can be a sender. 5. Press the appropriate button to set the function of the input to "Sender". The operator panel should display the available types of senders. 6. Press the appropriate button to select the type of sender this input will be. The operator panel should display the current event type of the sender. 7. Press the ADJUST button to configure the event type of the sender. 8. Press the (+) and (-) buttons to set the event type, which varies by type of sender. 9. Press the SAVE button to save your changes. 10. Return to the I/O Module menu. 11. Press the appropriate button to go to the Senders submenu. 12. Press the selection buttons to find the type of sender this input will be. The operator panel should display the current settings of the sender. 13. Press the ADJUST button to configure the sender. 14. Enter the appropriate settings for the sender. The settings vary by type of sender. 15. Press the SAVE button to save your changes.

5.1.1.6.1 Typical Electrical Characteristics of Various Sensors This table provides information for reference only. It should not be used to configure any devices that will be connected to the sensors.

NOTICE Use the documentation provided with a sensor to configure any device that will be connected to the sensor. Failure to do so may r esult in equipment damage.

TABLE 56.

TYPICAL ELECTRICAL CHARACTERISTICS OF VARIOUS SENSORS

Type of Sensor

Typical Characteristics

Oil temperature

600-2200 ohms

Exhaust temperature

80-400 ohms

Ambient air temperature

600-2200 ohms

Fuel level

600-2500 ohms

Alternator temperature

PT 100 RTD 100 ohms @ 0 C (32 F), 0.385 ohms/C (0.214 ohms/F)

5.1.1.7 How to Configu re an Outpu t o n a PCC 1301, PCC 1302, or PowerCommand 1.x 1. Go to the I/O Module menu. 2. Press the appropriate button to go to the Outputs submenu. 3. Press the selection buttons to find the output you want to configure. A030K737 (Issue 6)

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4. Press the ADJUST button to configure the output. 5. Enter the fault code that should be associated with the output. 6. Press the SAVE button to save your changes.

5.1.2

Using InPower to Configure the AUX 101 and AUX 102 You can use InPower to configure the AUX 101 and AUX 102, but there are no procedures for this in this manual.

5.2

Tools to Configur e a PCC 2100 AUX 101/102 You must use the InPower service tool to configure the AUX 101 and AUX 102 settings in the controller.

5.2.1

How to Disable or Enable an AUX 101 on the PCC 2100 In InPower, go to the AUX 101 Setup folder, and change the value of "AUX 101('s) Enable".

5.2.2

How to Configure a Switch on the PCC 2100 1. In InPower, go to the "AUX 101 Device #1 Inputs" folder. 2. Set the "Device #1 Input Sensor Type" parameter for the input that will be a switch. 3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a switch. 4. Save your changes in InPower.

5.2.3

How to Configure a Voltage Bias on a PCC 2100 1. In InPower, go to the "AUX 101 Device #1 Inputs" folder. 2. Set the "Device #1 Input Sensor Type" parameter to "Bias Sensor" for the input that will be a voltage bias. 3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a voltage bias. 4. Go to the "AUX 101 Setup" folder. 5. Set the "Voltage Bias Scale" parameter according to the voltage bias connection. • For a voltage bias connected to two power supplies (for example, +5 V and -5 V), set this parameter to the maximum increase in voltage the voltage bias can create. • For a voltage bias connected to one power supply (for example, +5 V and ground), set this parameter to two times the maximum increase in voltage the voltage bias can create. 6. Set the "Voltage Bias Enable" parameter to "Enable". 7. For a voltage bias connected to one power supply, set the "Voltage Adjust" parameter to the result of the following calculation. a. Start with the maximum increase in voltage the voltage bias can create. b. Divide it by the generator set nominal voltage. c. Multiply the result by -100.

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For a voltage bias connected to two power supplies, skip this step. 8. Save your changes in InPower.

5.2.4

How to Config ure a Speed Bias on a PCC 2100 1. In InPower, go to the "AUX 101 Device #1 Inputs" folder. 2. Set the "Device #1 Input Sensor Type" parameter to "Bias Sensor" for the input that will be a speed bias. 3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a speed bias. 4. Go to the "AUX 101 Setup" folder. 5. Set the "Speed Bias Scale" parameter to the maximum increase in RPM the speed bias can create. 6. Set the "Speed Bias Enable" parameter to "Enable". 7. Save your changes in InPower.

5.2.5

How to Configure an Output on a PCC 2100 1. In InPower, go to the "AUX 101 Device Outputs" folder for the AUX 101 to which the output belongs. 2. Set the "Device Output Relay Fault Code Mapping" parameter to the fault code that should be associated with the output. 3. Set the "Device Output Relay Enable" parameter to "Enable" for the output you want to configure. 4. Save your changes in InPower.

5.3

Tools to Configure a PowerCommand 2.x or 3.x AUX101/102 You must use one of these tools to configure the AUX101 and AUX102 settings in the controller. • Operator panel • InPower service tool • Modbus connection

5.3.1

How to Find the AUX101 Setup Screens in th e Operator Panel The AUX101 Setup screens are available on the main menu. 1. Go to the Home screen. 2. Change the selection in the graphical display until "AUX 101 Setup" is selected. Use the selection buttons to change page, if necessary. 3. Press OK.

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How to Configure a Switch on the PowerCommand 2.x or 3.x 1. Set "AUX 101 Analog Input Sensor Type" to "Switch Input - Active Closed" or "Switch Input - Active Open" for the input that will be a switch. 2. Enter a brief description of the event in "AUX 101 Input Fault Text" for the input that will be a switch. 3. Set "AUX 101 Input Function Pointer" to "Default" for the input that will be a switch. 4. Save your changes.

5.3.3

How to Configure an Additional Function for AUX101 Inputs on the PowerCommand 2.x or 3.x 1. Set "AUX 101 Analog Input Sensor Type" to "Switch Input - Active Closed" or "Switch Input - Active Open" for the input that will be a switch. 2. Set "AUX 101 Input Function Pointer" to the desired function for the input that will be a switch. If the selection is rejected, the desired function is already used by another input. 3. Set the appropriate settings for the desired function. The related settings vary by function. 4. Save your changes.

5.3.3.1 Example: Confi gur e AUX101 Inpu t #3 as a Low Fuel in Day Tank Switch on the PowerCommand 2.x or 3.x In this example, the Low Fuel in Day Tank Switch is active-closed, and the switch must be active for five seconds before the controller generates a fault. 1. Set "AUX101 0 Analog Input 3 Sensor Type" to "Switch Input - Active Closed". 2. Set "AUX101 0 Input 3 Function Pointer" to "Low Fuel in Day Tank Switch". 3. Set "Low Fuel in Day Tank Time" to 5 seconds. 4. Save your changes.

5.3.4

How to Configure an Analog Input on the PowerCommand 2.x or 3.x 1. Set "AUX 101 Analog Input Sensor Type" to "Analog Input" for the input that will be an analog input. 2. Set "AUX 101 Analog Input Function Pointer" to the desired function. 3. Set the appropriate settings for the desired function. The related settings vary by function. 4. Save your changes.

5.3.4.1 Example: Confi gur e AUX101 Input #4 as an Alt ernator Temperature Sensor on the PowerCommand 2.x or 3.x In this example, the alternator temperature sensor must be at least 300 degrees F for five seconds before the controller generates a fault. The out-of-range check is active, and the sensor must be outside 0.2-4.8 VDC for two seconds before the controller generates a fault. 1. Set "AUX101 0 Analog Input 4 Sensor Type" to "Analog Input". 48

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2. Set "AUX101 0 Analog Input 4 Function Pointer" to "Alternator Temperature 1". 3. Set "High Alternator Temperature 1 Threshold (Aux101)" to 300 degrees F. 4. Set "High Alternator Temperature 1 Time (Aux101)" to 5 seconds. 5. Set "Aux101 Alternator Temperature OOR High Limit" to 4.8 VDC. 6. Set "Aux101 Alternator Temperature OOR Low Limit" to 0.2 VDC. 7. Set "Aux101 Alternator Temperature OOR Time" to 2 seconds. 8. Set "Aux101 Alternator Temperature OOR Check Enable" to "Enable". 9. Save your changes.

5.3.4.2 Typical Electric al Characteristi cs of Various Sensor s This table provides information for reference only. It should not be used to configure any devices that will be connected to the sensors.

NOTICE Use the documentation provided with a sensor to configure any device that will be connected to the sensor. Failure to do so may r esult in equipment damage.

TABLE 57.

5.3.5

TYPICAL ELECTRICAL CHARACTERISTICS OF VARIOUS SENSORS

Type of Sensor

Typical Characteristics

Oil temperature

600-2200 ohms

Exhaust temperature

80-400 ohms

Ambient air temperature

600-2200 ohms

Fuel level

30-2500 ohms

Alternator temperature

PT 100 RTD 100 ohms @ 0 C (32 F), 0.385 ohms/C (0.214 ohms/F)

How to Configure an Output on the PowerCommand 2.x or 3.x 1. Set "AUX 101 Output Function Pointer" to the desired function for the output. 2. If the desired function is "Default", set "Aux 101 Output Fault/Event" to the fault code that should be associated with the output. 3. Save your changes.

5.3.5.1 Example: Confi gur e AUX101 Output #1 as a Low Coolant Level #2 Output on the PowerCommand 2.x or 3.x Low Coolant Level #2 is event/fault code 2977. 1. Set "Aux101 0 Output 1 Function Pointer" to "Default". 2. Set "Aux101 0 Output 1 Fault/Event" to 2977. 3. Save your changes. A030K737 (Issue 6)

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Configuring the AUX 101 and AUX 102 with the MCM3320 Set up the generator sets and the loads in the MCM3320. If the number of generator sets or loads requires an AUX 101 and AUX 102, the MCM3320 expects the AUX 101 and AUX 102 to be connected in a specific way, as indicated in the wiring diagrams.

6.1

Supplementary Interface Device (SID) A supplementary interface device (SID) is the combination of an AUX 101 and its companion AUX 102. Each SID is the interface for a certain range of generator sets and a certain range of loads.

6.1.1

Generator Sets by SID TABLE 58.

6.1.2

GENERATOR SETS BY SID

SID

Generator Sets

none

1-4

SID1

5-8

SID2

9-12

SID3

13-16

Loads by SID NOTICE SIDs are connected to loads, not load-add levels or load-shed levels .

TABLE 59.

6.1.3

LOADS BY SID

SID

Loads

SID0

1-6

SID1

7-10

SID2

11-14

SID3

15-18

SID Required A SID is required if either of these conditions are met. • Gen N kW Rating is not equal to zero, where N is any generator set in the range for that SID.

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• Load Add Shed Enable is Enabled, and Load N Device Type is not equal to None, where N is any load in the range for that SID. If a SID is required, the MCM must be able to communicate with the AUX 101 and AUX 102. If it cannot communicate, the MCM cannot control the generator sets and loads to which the SID is connected, and some features may not be active.

6.1.4

Legacy SID Override (Before V2.00) Prior to firmware V2.00, it was possible to set up more than four generator sets in the MCM, though the MCM could sense only four paralleling breakers. To handle this, some paralleling breakers were connected in parallel with each other to the same set of pins on the MCM, allowing the MCM to know when at least one of them is closed. Starting with V2.00, it is not possible to have a different number of generator sets and paralleling breakers. If V2.00 or later firmware is present in a legacy system that has more than four generator sets and the generator set paralleling breakers are connected in parallel to the MCM generator set main breaker position input, set Legacy SID Override to Enable. In this case, no SIDs are required.

6.1.5

Compatible Software Versio ns (AUX 101) TABLE 60.

COMPATIBLE SOFTWARE VERSIONS (AUX 101)

MCM3320

AUX 101

V2.00 or later

6.1.6

V1.48 or later

Summary of Monitor Points (AUX 101/102) TABLE 61.

SUMMARY OF MONITOR POINTS (AUX 101/102)

Setting

Description

SIDX Status (X = 0-3)

(Software v2.00 and later) Indicates the status of communication between the MCM3320 and the AUX 101. Possible values: Missing, Good, Connecting, No Exp Board, Not Applicable

PCCnet Communications Status

(Prior to software v2.00) Indicates the status of communication between the MCM3320 and the AUX 101. Possible values: Failed, Good, Wait

PCCNet Status

(v2.00 and later) Indicates the status of PCCNet communication. Possible values: No Connection, Connecting, Connected

Expansion Board CommunicationsX (X = blank, 1, 2, 3)

Indicates whether or not the AUX 102 is detected. Possible values: Disabled, Enabled

AUX101 Software Version (X = blank, 1, 2, 3)

Indicates the software version the AUX 101 is running.

Node Count for Remote IO

Indicates the number of AUX 101 the MCM3320 sees on the PCCNet network.

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Setting

Description

Load X Input 1 (X = 1-18)

If the load type is ATS, this indicates whether or not the emergency source is connected. If the load type is Breaker, this indicates the position of the A contact. Possible values: Not Available, Open, Closed

Load X Input 2 (X = 1-18)

If the load type is ATS, this indicates whether or not the normal source is connected. If the load type is Breaker, this indicates the position of the over current trip contact. Possible values: Not Available, Open, Closed

SIDX Input (X = 0-3)

Provides the status of the AUX 101/102 inputs as received by the MCM3320. This is the packet received by the MCM3320, whereas the Load X Input settings indicate the unpacked values.

SIDX Output 1/2 (X = 0-3)

Controls the status of the AUX 101/102 outputs as requested by the MCM3320. This is the actual packet sent by the MCM3320.

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6.2

AUX101 Board

FIGURE 24.

6.2.1

5-2015

AUX101 BOARD

AUX101 S1 The S1 button can be used to change the AUX101 device number.

6.2.2

AUX 101 Device Number Indicator The AUX 101 device number indicator displays the device number of this particular AUX 101 in a PCCNet network. The device number must be unique in the PCCNet network.

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6.2.3


AUX 101 Device Number by SID TABLE 62.

AUX 101 DEVICE NUMBER BY SID

SID

6.2.4

AUX 101 Device Number

SID0

0

SID1

1

SID2

2

SID3

3

Changing the AUX101 Device Number 1. Press and hold S1 for at least five seconds. On the AUX101 device number indicator, a small dot should appear next to the current device number. 2. Press and release S1 until the desired number is displayed. 3. Wait five seconds. After five seconds of inactivity, the new device number is set, and the small dot should disappear. 4. Disconnect and reconnect J14 to cycle power to the AUX101.

6.2.5

AUX 101 Indicators TABLE 63. AUX 101 INDICATORS

Indicator

6.2.6

SID0

SID1

SID2

SID3

DS1

This is on if the AUX 101 is connected to a PCCNet network and is operating normally.

DS2

This is on if the AUX 101 is not connected to the PCCNet network.

DS3

load 1 add

load 7 add

load 11 add

load 15 add

DS4

load 1 shed

load 7 shed

load 11 shed

load 15 shed

DS5

load 2 add

load 8 add

load 12 add

load 16 add

DS6

load 2 shed

load 8 shed

load 12 shed

load 16 shed

DS7

load 3 add

load 9 add

load 13 add

load 17 add

DS8

load 3 shed

load 9 shed

load 13 shed

load 17 shed

DS9

load 4 add

load 10 add

load 14 add

load 18 add

DS10

load 4 shed

load 10 shed

load 14 shed

load 18 shed

AUX 101 Connectors TABLE 64.

Connector

SID0

J1

AUX 101 CONNECTORS SID1

SID2

SID3

Connection to controller

J2

load 1 and load 2 add/shed




J3

load 3 add/shed

load 9 add/shed

load 13 add/shed

load 17 add/shed

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Connector

SID0

SID1

SID2

SID3

J4

load 4 add/shed

load 10 add/shed

load 14 add/shed

load 18 add/shed

J5

Connection to AUX 102

J11

load 1-4 input

load 7-10 input

J14

load 11-14 input

load 15-18 input

Power supply

J10 is not connected in MCM3320 applications.

6.2.7

Pin

Description

J1-1

Output power B-

J1-2

Output power B+

J1-3

PCCNet A

J1-4

PCCNet B

J1-5

System wakeup

6.2.8

56

AUX101 J1

FIGURE 25.

AUX101 J1

TABLE 65.

AUX101 J1

FIGURE 26.

AUX 101 J2

AUX 101 J2

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TABLE 66.

AUX 101 J2

Pin

Contact

SID0

SID1

SID2

SID3

J2-1

normally-open

load 1 add

load 7 add

load 11 add

load 15 add

J2-2

common

J2-3

normally-closed

J2-4

normally-open

load 1 shed

load 7 shed

load 11 shed

load 15 shed

J2-5

common

J2-6

normally-closed

J2-7

normally-open

load 2 add

load 8 add

load 12 add

load 16 add

J2-8

common

J2-9

normally-closed

J2-10

normally-open

load 2 shed

load 8 shed

load 12 shed

load 16 shed

J2-11

common

J2-12

normally-closed

6.2.9

AUX 101 J3

FIGURE 27.

AUX 101 J3

TABLE 67.

AUX 101 J3

Pin

Contact

SID0

SID1

SID2

SID3

J3-1

normally-open

load 3 add

load 9 add

load 13 add

load 17 add

J3-2

common

J3-3

normally-closed

J3-4

normally-open

load 3 shed

load 9 shed

load 13 shed

load 17 shed

J3-5

common

J3-6

normally-closed

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6.2.10 AUX 101 J4

FIGURE 28.

AUX 101 J4

TABLE 68.

AUX 101 J4

Pin

Contact

SID0

SID1

SID2

SID3

J4-1

normally-open

load 4 add

load 10 add

load 14 add

load 18 add

J4-2

common

J4-3

normally-closed

J4-4

normally-open

load 4 shed

load 10 shed

load 14 shed

load 18 shed

J4-5

common

J4-6

normally-closed

6.2.11 AUX101 J5 If the AUX101 is connected to an AUX102, this is connected to J6 on the AUX102.

FIGURE 29.

AUX101 J5


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6.2.12 AUX 101 J11

FIGURE 30. AUX 101 J11 TABLE 69.

AUX 101 J11

Pin

Contact

SID0

SID1

SID2

SID3

J11-1

reference input

load 1

load 7

load 11

load 15

J11-2

position A or normal source

J11-3

reference input

J11-4

trip or emergency source

J11-5

reference input

load 2

load 8

load 12

load 16

J11-6


J11-7

reference input

J11-8


J11-9

reference input

load 3

load 9

load 13

load 17

J11-10


J11-11

reference input

J11-12


J11-13

reference input

load 4

load 10

load 14

load 18

J11-14


J11-15

reference input

J11-16


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6.2.13 AUX101 J14

Pin

AUX101 J14

TABLE 70.

AUX101 J14

Description

J14-1

Input power B+

J14-2

Input power B-

6.3

FIGURE 31.

AUX102 Board

FIGURE 32.

60

AUX102 BOARD

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6.3.1


AUX 102 Indicators TABLE 71. AUX 102 INDICATORS

Indicator

SID0

SID1

SID2

SID3

DS1

load 5 add

load demand generator set 5



DS2

load 5 shed




DS3

load 6 add




DS4

load 6 shed




6.3.2

DS5

not used

DS6

not used

DS7

not used

DS8

not used

AUX 102 Connectors TABLE 72.

AUX 102 CONNECTORS

Connector

SID0

SID1

SID2

SID3

J1

load 5-6 add/shed, normally-open

load demand generator set 5-8, normally-open



J2

load 5-6 add/shed, common

load demand generator set 5-8, common



J3

load 5-6 add/shed, normally-closed

load demand generator set 5-8, normally-closed



J4

load 5-6 input

generator set 5-8 paralleling breaker position



J5

Chassis ground

J6

Connection to AUX 101

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AUX 102 J1

FIGURE 33.

AUX 102 J1

J1 provides normally-open contacts for the output relays. TABLE 73.

6.3.4

AUX 102 J1

Pin

SID0

SID1

SID2

SID3

J1-1

load 5 add




J1-2

load 5 shed




J1-3

load 6 add




J1-4

load 6 shed




J1-5

not used

J1-6

not used

J1-7

not used

J1-8

not used

AUX 102 J2

FIGURE 34.

AUX 102 J2

J2 provides common contacts for the output relays.

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TABLE 74.

6.3.5

AUX 102 J2

Pin

SID0

SID1

SID2

SID3

J2-1

load 5 add




J2-2

load 5 shed




J2-3

load 6 add




J2-4

load 6 shed




J2-5

not used

J2-6

not used

J2-7

not used

J2-8

not used

AUX 102 J3

FIGURE 35.

AUX 102 J3

J3 provides normally-closed contacts for the output relays. TABLE 75.

AUX 102 J3

Pin

SID0

SID1

SID2

SID3

J3-1

load 5 add




J3-2

load 5 shed




J3-3

load 6 add




J3-4

load 6 shed




J3-5

not used

J3-6

not used

J3-7

not used

J3-8

not used

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6.3.6

AUX 102 J4

FIGURE 36.

AUX 102 J4

TABLE 76.

AUX 102 J4

Pin

SID0

SID1

SID2

SID3

J4-1

load 5 position A or normal source connected

generator set 5 paralleling breaker position



J4-2 J4-3

reference input load 5 trip or emergency source connected


J4-4 J4-5

J4-7



reference input load 6 position A or normal source connected


J4-6



reference input load 6 trip or emergency source connected


J4-8

6.3.7

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reference input

AUX102 J5 J5 is connected to a good earth ground.

6.3.8

AUX102 J6 This is connected to J5 on the AUX101.

FIGURE 37. 64

AUX102 J6 A030K737 (Issue 6)

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6.4

Connecting to an AUX 101 or AUX 102 Using InPower You can use InPower to update the firmware in the AUX 101 or AUX 102. Connect to the AUX 101 using J1. You cannot connect directly to an AUX 102 using InPower. You should connect to the AUX 101 to which the AUX 102 is connected instead.

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Configuring the AUX 101 and AUX 102 with the PC500/550 The PC500/550 communicates to the AUX 101/102 device via Modbus protocol.

7.1

Configuring Modbus Communication Parameters The InPower service tool is used to configure Modbus communication parameters. Connect the Inpower service tool cable between the PC and J1 on the AUX 101. Set the AUX 101 device number to 0, 1, 2, or 3. TABLE 77.

SUPPORTED MODBUS SETTINGS

Setting

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Setting Values

Modbus Address

As supported by Modbus protocol

Baud Rate

2400 4800 9600 19200 38400

Stop Bit

1 2

Parity

None Even Odd

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7. Configuring the AUX 101 and AUX 102 with the PC500/550

7.2

AUX101 Board

FIGURE 38.

7.3

5-2015

AUX101 BOARD

AUX 101 S1 Device Number The S1 button is used to change the AUX 101 device number. To select the Modbus device number: 1. Press and hold S1 for at least 5 seconds. On the AUX 101 device number indicator, a small dot should appear next to the current device number. 2. Press and release S1 until "H" is displayed. 3. Wait 5 seconds. After 5 seconds of inactivity, the new device number is set and the small dot should disappear. 4. Disconnect and reconnect J14 to cycle power to the AUX 101.

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7.4


Configuring AUX 101 Using PC500/550 User Interface 1. Connect AUX 101 (J1) to PC500/550 (TB2) using a Modbus communication cable. 2. Select Device Configuration from the Setup Menu. 3. Select Add New Device and select I/O Device from the drop-down list. 4. Enter the required information.

NOTICE The entered Modbus Address must be the same as the AUX 101 Modbus address configured using the InPower service tool. 5. To add AUX 101 inputs and outputs, select Sensors and Output Controls from the Setup Menu.

NOTICE Sensors and output controls are listed in the Site IOs details page after they are configured.

7.5

I/O Control Capabilities Over Modbus The following table provides the Modbus register parameters for the AUX 101 with a description of possible values and their read/write capabilities over Modbus.

NOTICE The table provides general information for any Modbus Master. Parameters, such as Software Version and Device Type, are not used by the PC500/550 user i nterface.

TABLE 78. Parameter(s)

I/O CONTROL CAPABILITIES OVER MODBUS Description

Modbus Control

Modbus Settings

Device ID, Baud Rate, Parity, Stop Bits

Read Only (configurable using InPower Service Tool)

Software Version

–

Read Only

Device Type

59 (default)

Read Only

AUX102 Availability

Available/Not Available

Read Only

Input 1–8 Settings

Analog, Discrete Active High/Low

Read/Write (configurable over Modbus)

Input 1–8 Status

Voltage (for Analog inputs), Active/Inactive (for Discrete Active High/Low inputs)

Read Only

Input 9–12 Settings

Active/Inactive (for Discrete Active Low inputs)

Read/Write (NOT configurable over Modbus)

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Parameter(s)

Description

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Modbus Control

Current Sources 1–4

Analog, Discrete Active High/Low


Outputs 1–8

Active/Inactive


Outputs 9–16

Active/Inactive


Refer to Modbus Register Mapping (A029X159) for additional information about the Modbus registers.

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Troubleshooting

8.1

DS1 and DS2 Are Off DS1 and DS2 are off, but the board should have power.

8.1.1

Checking the Power Connections Make sure the power supply wires are connected securely.

8.1.2

Checking the Wires Measure the resistance of each wire. If the resistance is greater than 10 replace the wire.

8.1.3

Ω,

check any fuses or breakers in the harness. Otherwise,

Checking the Power Supply Measure the voltage provided by the power supply. If the voltage is outside the allowed range, troubleshoot the power supply.

8.2

DS2 Is On DS2 is on, but the board should be connected to a PCCNet network.

8.2.1

Checkin g the PCCNet Connection s Make sure the PCCNet wires are connected securely to J1-3 (PCCNet A) and J1-4 (PCCNet B).

8.2.2

Checking the Wires Measure the resistance of each wire. If the resistance is greater than 10

8.2.3

Ω,

replace the wire.

Checking the Device to Which the Board Is Connected If the device does not appear to be communicating on its port, troubleshoot the device.

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Manufacturing Facilities

NORTH AMERICA

EMEA, CIS

ASIA PACIFIC

Cummins Power Generation Limited 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Cummins Power Generation Limited Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

Cummins Power Generation Limited 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

Phone +1 763 574 5000 Toll Free +1 800 888 6626 Fax +1 763 574 5298

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

BRAZIL

CHINA

INDIA

Rua Jati, 310, Cumbica Guarulhos, SP 07180-900 Brazil

Cummins Power Generation 2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R.China

Cummins India Ltd, Power Generation Business Unit, Plot No B-2, SEZ Industrial Area, Village-Nandal & Surwadi, TalukaPhaltan Dist- Satara, Maharashtra 415523 India

Phone +55 11 2186 4195 Fax +55 11 2186 4729

Phone +86 10 5902 3000 Fax +86 10 5902 3199

Phone +91 021 66305514

LATIN AMERICA

MEXICO

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico

Phone +1 954 431 551 Fax +1 954 433 5797

Phone +52 444 870 6700 Fax +52 444 824 0082

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Appendix A. Wiring Diagrams Table of Contents Figure 39. AUX 101, 0630-3142, Sheet 1 of 2 ............................................................................................. 77 Figure 40. AUX 102, 0630-3142, Sheet 2 of 2 ............................................................................................. 78 Figure 41. PCC 1301 and AUX 101/102, 0630-2926, Sheet 1 of 1 ............................................................. 79 Figure 42. PCC 2100 and AUX 101/102, 0612-6764, Sheet 1 of 1 ............................................................. 80 Figu re 43. PCC 1302/PowerCo mman d 1.x and AUX 101/102, 0630-3440, Sheet 1 of 2 ......................... 81 Figure 44. PowerCommand 2.x/3.x and AUX 101/102, 0630-3440, Sheet 2 of 2 ..................................... 82 Figure 45. MCM3320 and AUX 101/102, 0630-3133, Sheet 1 of 8 ............................................................. 83 Figure 46. MCM3320 and AUX 101/102, 0630-3133, Sheet 2 of 8 ............................................................. 84 Figure 47. MCM3320 and AUX 101/102, 0630-3133, Sheet 3 of 8 ............................................................. 85 Figure 48. MCM3320 and AUX 101/102, 0630-3133, Sheet 4 of 8 ............................................................. 86 Figure 49. MCM3320 and AUX 101/102, 0630-3133, Sheet 5 of 8 ............................................................. 87 Figure 50. MCM3320 and AUX 101/102, 0630-3133, Sheet 6 of 8 ............................................................. 88 Figure 51. MCM3320 and AUX 101/102, 0630-3133, Sheet 7 of 8 ............................................................. 89 Figure 52. MCM3320 and AUX 101/102, 0630-3133, Sheet 8 of 8 ............................................................. 90

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Wiring Diagrams

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Wiring Diagrams

FIGURE 39. AUX 101, 0630-3142, SHEET 1 OF 2

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Wiring Diagrams

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FIGURE 40. AUX 102, 0630-3142, SHEET 2 OF 2

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Wiring Diagrams

FIGURE 41. PCC 1301 AND AUX 101/102, 0630-2926, SHEET 1 OF 1

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Wiring Diagrams

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FIGURE 42. PCC 2100 AND AUX 101/102, 0612-6764, SHEET 1 OF 1

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Wiring Diagrams

FIGURE 43. PCC 1302/POWERCOMMAND 1.X AND AUX 101/102, 0630-3440, SHEET 1 OF 2

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Wiring Diagrams

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FIGURE 44. POWERCOMMAND 2.X/3.X AND AUX 101/102, 0630-3440, SHEET 2 OF 2

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Wiring Diagrams

FIGURE 45. MCM3320 AND AUX 101/102, 0630-3133, SHEET 1 OF 8

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Wiring Diagrams

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Wiring Diagrams


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Wiring Diagrams

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