®
PowerCommand Control 1302 Operator Instructions
Table of Contents SECTION 1
TITLE
PAGE
PCC 1302 Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC 1302 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Status Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S l ee p M ode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuring Sleep In Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with a Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with a Manual Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with a Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations without a Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Previous Main Menu Button
1 -1 1-1 1 -2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1 -3 1-4 1-4 1 -5 1-5 1-5 1-6 17
Table of Contents SECTION
TITLE
(Continued) PAGE
Selecting Auto, Manual Run, and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . . . . . Selecting Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-17 1-17 1-18 1-19 1-19 1-19 1-20 1-20 1-20 1-22 1-22 1-22 1-22 1-22 1-24 1-26 1-26 1-26
1. PCC 1302 Control Operation DS1 LED STATUS INDICATOR
J17
J18 J22
TB1 J12 J25 TB15
A PCC 1302 installation may also include the following options. •
If a control panel is mounted on the genset (local display), one additional control panel can be mounted up to 4000 feet from the genset (remote displays). A setup menu in the optional display panel is required to designate a display as Local or Remote.
•
Local status indicator lamp driver
•
Remote and local emergency stop
•
Four configurable inputs
•
Annunciator fault inputs 1, 2, and 3 − These outputs can be used when an annunciator is installed as part of an PCCNet interface connected to TB1-2 and TB1-3. Grounding one of these inputs on the annunciator activates the corresponding warning or shutdown sequence. Three Customer Annunciator Text message submenus are supplied to enter the event type and description (see page 1-28).
•
ECM CAN engine interface
is flashed, followed by a half-second pause and the third digit is flashed, followed by a halfsecond pause and then the fourth digit is flashed, followed by a two-second pause. NOTE: Only the last shutdown fault is flashed.
OPERATING MODES The PCC 1302 works with a Manual Run/Off/Auto switch, used to control genset operating modes. This capability is located either in the harness (switch) or is integrated into the optional control panel.
Off Mode When in Off mode, the control does not allow the genset to start. If the genset is already running and the control is set to Off, it initiates a normal shutdown sequence.
Manual Run Mode When in Manual Run mode, the genset starts and continues to run until the control is put into the Off mode. While in Manual Run mode, the remote start
Emergency Stop Mode When an optional emergency stop button is used, it immediately shuts down the generator set, bypassing any time delay stop. If an optional emergency stop is not used, the local and remote E-stop signals must be shorted to GND. The red Shutdown LED lights and one of the two emergency stop fault codes (1433 − Local Emergency Stop or 1434 − Remote Emergency Stop) is either displayed (installations with a control panel) or flashed (installations with a status indicator lamp), depending on which was activated last. To reset the control, close (disable) the active emergency stop button(s) and perform a fault reset (see page 1-9).
Sleep Mode The PCC 1302 control enters a low power (sleep) mode of operation where the current draw is not greater than 60 milliamps (DC) at normal battery voltage levels. The control is set to enter sleep mode after five minutes in Off mode or Auto mode, if configured. (Sleep mode can be disabled if a jumper is installed connecting TB15-1 to TB15-5.)
5. Disconnect the PCC 1302 from InPower. Installations with a Control Panel Sleep mode is automatically enabled on the control panel. The PCC 1302 control determines that it should sleep when the display panel has had no key presses for five minutes and wake-up signals are inactive. The control system can be awakened by pressing the keypad on the control panel or by activating any wake-up input. Installations with a Manual Run/Off/Auto Switch For installations that utilize an Manual Run/Off/Auto switch located in the harness, the control awakes from sleep mode if Manual Run mode is selected. The control will also wake up if Auto mode is selected and the control is configured to stay awake when in Auto mode, Wake-In-Auto = Enabled.
Battle Short Mode The purpose of Battle Short is to satisfy local code requirements, where necessary. To use this feature, the necessary software must either be
Installations with a Control Panel Battle Short can be enabled or disabled (set to Active or Inactive) using the control panel. The PC service tool is required to enable the Battle Short mode feature. Contact an authorized service center for assistance. Before Battle Short can be used on installations with the display panel, the Switch Input setting on the Battle Short submenu must be set to “Operator Panel” (see page 1-11). In addition, Battle Short mode must be enabled (set to Active) in the Battle Short submenu (see page 1-11). When Battle Short mode is enabled, the Warning status indicator lights, and code 1131 − Battle Short Active is displayed. When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains lit even though the genset continues to run. Fault code 1416 − Fail to Shut Down is displayed. If the , , or button is pressed to acknowledge the fault, the fault message is cleared from the display but remains in the Fault History file. Battle Short is suspended and a shutdown occurs
(see page 1-11) and select “Inactive.” Fault code 1123 − Shutdown After Battle Short is then displayed. Installations without a Control Panel A Manual Run/Off/Auto switch must be installed in installations that do not include a control panel. Battle Short can be turned on or off with a customer installed external switch connected to one of the four configured inputs. The PC service tool is required to enable the Battle Short mode feature and to enable the external Battle Short switch using one of the four available customer inputs. Contact an authorized service center for assistance. When Battle Short mode is enabled and an overridden shutdown fault occurs, the genset continues to run and the status indicator lamp flashes the shutdown fault code. See “Local Status Output” on page 1-2 for information on interpreting the status indicator light. Battle Short is suspended and a shutdown occurs immediately if: Any of the following shutdown faults occurs.
LED INDICATORS
GRAPHICAL DISPLAY
OFF MODE BUTTON HMI1211
DISPLAY MENU SELECTION BUTTONS
PREVIOUS MENU LEVEL BUTTON
FIGURE 1-2. PCC 1302 OPTIONAL CONTROL PANEL
CONTROL PANEL
TABLE 1-1. SYMBOLS
Display Menu Selection Buttons Four momentary soft-key buttons are used to step through the various menus and to adjust parameters. These selection buttons are “active” when a word or symbol in the graphical display is shown above the button. Some submenus do not include any active buttons. The function of the four selection buttons varies with each menu. •
•
•
When the symbol is displayed, the selection button can be used to switch to Auto mode.
tor menu that was displayed before the Auto or Manual Run mode was selected. •
When ADJUST is displayed, the selection button is used to display an adjustable menu. When the ADJUST button is pressed, the first adjustable parameter or value in the submenu is highlighted.
•
When the symbol is displayed, the selection button is used to navigate to an editable field within a menu.
•
When the + and − symbols are displayed, the selection buttons are used to increase or decrease a parameter or value shown on the screen.
When the symbol is displayed, the selection button can be used to switch to Manual Run mode.
When changing values, pressing the button below the + symbol increase the value and pressing the button below the − symbol decreases the value.
When the up and down triangles ( and ) are displayed, the selection buttons are used to navigate between a series of submenus. •
NOTE: When any Operator menu is displayed, a series of Service menus can be viewed by simultaneously pressing the and selection buttons for two
When SAVE is displayed, the selection button is used to save changes made in a submenu. If the Previous Menu button is pressed before pressing SAVE, the changes are not saved.
Previous Main Menu Button Press the menu.
button to view the previous main
NOTE: In the Screen Adjust menu, settings are not saved when the button is pressed.
If the button is pressed during genset operation (manual or remote start), the engine immediately shuts down and the control enters the Off mode. If possible, this hot shutdown should be avoided to help prolong the reliability of the genset.
Not In Auto Indicator This red lamp is lit when the control is not in the Auto mode.
Shutdown Indicator
OFF BUTTON
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be started when this lamp is on. After the condition is corrected, the lamp can be reset by performing a fault reset. When Battle Short mode is enabled and an overridden shutdown fault occurs, the Shutdown lamp is lit even though the genset continues to run.
Warning Indicator This yellow lamp is lit whenever the control detects a warning condition. This lamp is automatically shut off when the warning condition no longer ex-
CONTROL PANEL SYSTEM MESSAGES A system pop-up message is displayed when the event it is displaying becomes active. These popup messages remain displayed until pre-empted by another pop-up message or until the or the display buttons is pressed or the event has expired. Once the or the button is pressed, the previous screen is redisplayed.
until communications have been re-established (see Figure 1-5). The LEDs then return to the state determined by the control.
Communication Messages System messages are displayed for initial powerup or when there is a subsequent loss of communications. Auto and Manual Run modes can also be selected when communication messages are displayed (for more information, see page 1-18). Upon initial power-up, the message “Establishing communication with control” is displayed (see Figure 1-4). This menu also displays the screen’s software number and version.
FIGURE 1-5. RE-ESTABLISHING COMMUNICATIONS MESSAGE
If either communication message remains displayed (cannot view other menus), this is an indication that communications between the control panel and the control board is lost. Contact an authorized service center for service.
Event Messages
SCRN PN03266796 V#.##
When pre-set events (start or stop) are activated, Event messages are displayed showing the time remaining until the event occurs (see Figure ).
Status Messages Status messages for some events are displayed on the optional control panel with a code number but are not announced with a lamp indicator. Text status messages include the event code, a short description, and the time the event occurred. Symbolic status messages include the event code and symbols to indicate the type of event that occurred. On Full Authority Electronic engines, the engine controller saves data after each run. During this time, the display displays the message shown in Figure 1-7. The generator can still be started while the ECM Datasave is in progress.
Shutdown faults can also be acknowledged when in Auto mode by using an external customer-supplied remote fault reset switch. This ability must be enabled by setting the Remote Fault Reset Enabled trim to “Enabled” (disabled by default) using InPower. The remote fault reset switch must be wired into one of the four configurable inputs. The chosen configurable input should have its function mapped to the “Fault Reset” function. To reset the fault, the remote start command must be removed prior to the remote fault reset switch being activated. Faults are removed from the display when they are cleared. NOTE: Pressing the or button also clears the fault from the front panel display. Faults are re-announced if they are detected again after being acknowledged.
FIGURE 1-7. DATASAVE STATUS MESSAGE
Fault = WARNING
FAULT/STATUS CODES Table 1-2 provides a list of fault and status codes, types, displayed messages/symbols, descriptions, and fault categories (CTG). Category A Fault Codes: Pertain to engine or alternator shutdown faults that require immediate repair by trained and experienced service personnel (generator set non-operational). The control prevents the generator set from being restarted if a shutdown fault is not corrected. Category B Fault Codes: Consist of faults that can affect generator set performance or can cause
engine, alternator, or connected equipment damage. Operate the genset only when it is powering critical loads and cannot be shut down. Category B faults require repair by trained and experienced service personnel. Category C Fault Codes: Consist of faults that are repairable by site personnel. Service will be required by trained and experienced service personnel if site personnel cannot resolve the problem. Category D Fault Codes: Indicates non-critical operational status of generator set, external faults, or customer fault inputs. These faults require repair by trained and experienced service personnel.
TABLE 1-2. FAULT AND STATUS CODES DISPLAYED MESSAGE/SYMBOLS CTG CODE C
A
LAMP
TEXT VERSION
115 ** Shutdown HIGH COOLANT TEMP 121
SYMBOLIC VERSION
115
Shutdown SPEED SIGNAL LOST
121
DESCRIPTION Indicates that the engine coolant temperature is above normal and has reached the shutdown trip point. Indicates that no magnetic pickup pulses were sensed for a Loss of Speed delay. If
TABLE 1-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE C
359
LAMP
TEXT VERSION
SYMBOLIC VERSION
Shutdown FAIL TO START
359 A
C
415 ** Shutdown LOW OIL PRESSURE 441 **
C
442 **
B
1123 *
C
D
Warning
LOW BATTERY
Warning
HIGH BATTERY
Shutdown SHUTDOWN AFTER BS
1131 *
Warning
BATTLE SHORT ACTIVE
1311
Configur- Customer Fault
415
DESCRIPTION The genset has failed to start after a set number of crank attempts. This indicates a possible fuel system problem (engine cranks but fails to start). Indicates the engine oil pressure has dropped below normal and has reached the shutdown trip point.
441
Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation can occur.
442
Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur.
1123 1131
A shutdown fault occurred while the Battle Short mode was enabled. Indicates that the control is in Battle Short mode − used to bypass several fault shutdowns for genset operation during emergencies. The nature of the fault is an optional
TABLE 1-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE C
C
1435 **
1438
C
1442 **
A
1446 **
A
1447 **
LAMP
Warning
TEXT VERSION LOW COOLANT TEMP
SYMBOLIC VERSION
1435
Indicates that the engine coolant temperature is below the adjusted setpoint. This may indicate that the coolant heater is not operating or is not circulating coolant.
1438
The genset has failed to sense rotation for two start attempts. This indicates a possible fault with the control, speed sensing, or the starting system.
Shutdown FAIL TO CRANK
Warning
WEAK BATTERY
DESCRIPTION
1442
Indicates that the genset battery voltage is below battery thresholds during cranking.
1446
Indicates that the one or more measured AC output voltages has exceeded the threshold for longer than a specified time limit. The threshold and time limits are 130% of nominal for 0 seconds or 110% of nominal for 10 seconds.
Shutdown HIGH AC VOLTAGE
Shutdown LOW AC VOLTAGE
1447
Indicates that the measured AC output voltage is below the threshold for longer than a specified time limit. The threshold
TABLE 1-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE D
1944
LAMP
TEXT VERSION
Warning ANNUNCIATOR OUTPUT CONFIGURATION ERROR
A
2335
Shutdown EXCITATION FAULT
C
2676
SYMBOLIC VERSION
1944 2335
Shutdown ALTERNATOR
2677
Shutdown FAIL TO STOP
A
2972 **
Shutdown FIELD
B
2678 **
OVERLOAD
Warning
CHARGER FAILURE
Indicates a mismatch in the configuration of one of the annunciator relay outputs.
Indicates that a loss of voltage or frequency sensing from the generator has occurred. Indicates the measured alternator line frequency and measured alternator excitation frequency do not agree.
FREQUENCY CONFLICT B
DESCRIPTION
2677 2972
The genset continues to run after receiving a stop command from the controller. Indicates that the Field Voltage has been above 70V for 8 seconds. Indicates the battery charging alternator has not reached a acceptable voltage range within the selected time period (default = 120 seconds). This warning is also displayed if your
ADJUSTING DEFAULT SETTINGS
OPERATOR MENUS
The optional control panel can be set up to display with SAE or SI units of measurement.
Figures 1-10 and 1-11 show block representations of the following Operator menus.
For more information, see the Adjust Screen menu shown on page 1-26.
SAVING YOUR CHANGES
• •
Engine Status Alternator Status
•
Line-to-Line Voltage
•
Line-to-Neutral Voltage
All adjustments made to menus are temporary until the SAVE button is pressed. If the SAVE button is pressed and the engine is running, the adjustments are not saved until after the engine speed is zero. If power is lost to the control before a SAVE is executed, all temporary adjustments are lost.
To navigate between the Operator menus, press the buttons next to the and symbols in the graphical display.
Adjustments to the following are stored in flash memory in the optional display panel.
The Operator menus can be used to select Auto or Manual Run modes (see page 1-18).
•
Contrast
•
Brightness
•
Units Local or remote display
• • •
Symbols or text displayed Access code required for mode change to Auto or Manual Run
•
Alternator Amperage
Engine Status Menu This menu displays the engine starting battery voltage, engine coolant temperature, engine oil pressure, and hours of engine operation.
Alternator Status Menu This menu displays genset load (in kVA), frequen-
OPERATOR MENUS − Text Version
THREE PHASE
OPERATOR MENUS − Symbolic Version
THREE PHASE
SELECTING AUTO, MANUAL RUN, AND OFF MODES Auto, Manual Run, and Off modes can be selected: •
From any of the Operator menus
•
When the message “Establishing communication with control” is displayed
•
When the message “Re-establishing communication with control” is displayed
Switching to Auto, Manual Run, or Off mode can be restricted to authorized personnel. If a control panel is set up with the mode change access code feature enabled, an access code must first be entered before the mode can be changed. The mode change access code feature is enabled through the Display Setup submenu (see page 1-14). The Auto or Off mode switch status is saved in nonvolatile memory when it changes. When the control panel powers up (after sleeping or upon battery removal), the switch status is restored to its previous saved state.
2. Press the arrow selection button to the next numeric character.
to move
3. Press the button below the + or − symbols until the value reads “2.” 4. Press the arrow selection button to the next numeric character.
to move
5. Press the button below the + or − symbols until the value reads “1.” 6. After you have completed entering the password, press the arrow selection button . NOTE: If an incorrect password is entered, the Operator menu that was displayed before Auto, Manual Run, or Off mode was selected is redisplayed.
TEXT VERSION
Selecting Auto Mode To switch to Auto mode (see Figure 1-13), 1. Press the button on any of the Operator menus or the “Establishing/Re-establishing communication with control” menus. 2. If the mode change access code feature is enabled, the Mode Change Access Code menu is displayed. Enter the mode change access code as described above. 3. A menu with alternating arrows is displayed above a second symbol. Press the second button. The Operator menu that was displayed before Auto mode was selected is redisplayed. To disable Auto mode, press the
THIS MENU IS DISPLAYED ONLY IF THE MODE CHANGE ACCESS CODE FEATURE IS ENABLED
button.
NOTE: Manual Run mode can also be selected while in Auto mode.
ALTERNATING ARROWS ARE DISPLAYED
Selecting Manual Run Mode To switch to Manual Run mode (see Figure 1-14), To switch to Manual Run mode, 1. Press the button on any of the Operator menus or the “Establishing/Re-establishing communication with control” menus. 2. If the mode change access code feature is enabled, the Mode Change Access Code menu is displayed. Enter the mode change access code as described on the previous page. 3. A menu with alternating arrows is displayed above a second symbol. Press the second button. The Operator menu that was displayed before Manual Run mode was selected is redisplayed. To disable Manual Run mode, press the
button.
NOTE: Auto mode can also be selected while in
THIS MENU IS DISPLAYED ONLY IF THE MODE CHANGE ACCESS CODE FEATURE IS ENABLED
ALTERNATING ARROWS ARE DISPLAYED
SERVICE MENUS Figure 1-15 shows a block representation of the menus available from the Service Menus. The first Service Menu can be viewed from any of the Operator menus by simultaneously pressing the and selection buttons for two seconds. The first Service Menu provides access to the following menus: •
Setup Menus − Used by Service personnel. Adjusting the Setup menus is restricted by a password. To view the Setup menus only, press the VIEW button on the Setup password menu.
•
History / About − see page 1-22
•
Screen Adjust − see page 1-26
To return to the Operator menu that was displayed prior to viewing the Service Menu, press the button. The second Service Menu can be viewed by pressing the selection button on the first Service Menu. The second Service Menu provides access to the following menus:
The third Service Menu can be viewed by pressing the selection button on the second Service Menu. The third Service Menu provides access to the Network Status menus.
Status Menu The Status menu is displayed when the (5) button is pressed on the second Service Menu. The Status menu shows the following: •
Voltage regulator (drive) level, in percentage of duty cycle
•
Governor regulator (drive) level, in percentage of duty cycle. This value is only displayed if the governor is enabled.
Network Status Menus The Network Status menus are displayed when the (7) button is pressed on the third Service Menu. Two menu are used to display the quantity of the following devices that are connected to the network. •
Universal Annunciators
1ST SERVICE MENU
SETUP MENUS SEE PAGE 1-4
HISTORY / ABOUT MENUS SEE PAGE 1-22
SCREEN ADJUST MENU SEE PAGE 1-26
HISTORY / ABOUT MENUS Figure 1-16 shows a block representation of the History / About menu. The first History / About submenu is displayed when the (2) button is pressed on the Service Menu (see Figure 1-15). Press the buttons next to the and symbols in the graphical display to navigate between the History / About submenus. Press the button to return to the Service Menu.
About Genset Submenus Two submenus display the generator set model number, control number, and genset application frequency rating.
About Control Submenu This submenu displays the control’s part number, serial number (up to 11 characters), software part number (up to 9 characters), and software version.
History Submenu
About Display Submenu
This submenu displays the number of engine starts, hours of operation for the engine, and hours of operation for the control.
This submenu displays the optional control panel software part number, software version, screen part number, and screen version of the display.
HISTORY / ABOUT MENUS
FAULT HISTORY MENU Figure 1-18 shows a block representation of the Fault History menu. The first Fault menu is displayed when the (4) button is pressed on the second Service Menu (see Figure 1-15). If there are any active fault submenus, an “Active Fault” heading is displayed for the most recent active fault. All other fault submenus display a “Fault History” heading. Five of the most recent faults can be viewed. An example of how a fault code is displayed is shown in Figure 1-17.
Information on faults is included in Table 1-2 on page 1-10.
TIME FAULT OCCURRED FAULT CODE
FAULT DESCRIPTION
Press the buttons next to the and symbols in the graphical display to navigate between menus. Press the
button to return to the Service Menu.
FIGURE 1-17. FAULT HISTORY MENU EXAMPLE
FAULT HISTORY MENU
Active Fault
Fault 1
OR
Fault 2
SCREEN ADJUST MENU Figure 1-19 shows a block representation of the Screen Adjust menu. The Screen Adjust menu is displayed when the (3) button is pressed in the first Service Menu (see Figure 1-15).
NOTE: If the Previous Menu button is pressed before pressing the SAVE button, the changes are not saved. 5. Press the Menu.
button to return to the Service
Screen Adjust Menu
Adjusting Values/Parameters 1. Press the ADJUST selection button to select the first parameter or value to be changed. 2. Press the + or − selection buttons to adjust values or select parameters. 3. Press the arrow selection button to navigate to the next or previous adjustable value or parameter. 4. After adjusting values/selecting parameters, press the SAVE button to save your settings.
This menu allows for adjusting the screen’s contrast and brightness and for selecting the units of measurement (SAE or SI) to be displayed. and Brightness: Press the + or − selection buttons to adjust the screen’s contrast and brightness. Changing the brightness setting also affects the brightness of the LEDs on the control panel.
• Contrast
the + or − selection buttons to select SAE ( F, PSI) or SI (C, kPa) units of measurement to be displayed.
• Units: Press
SCREEN ADJUST MENU
J29 − 6
HMI2xx orHMI3xx Display Partnumbers HMI220: 0300−6314 HMI320: 0300−6315 J28 Mate: 0323−2091 J29 Mate: 0323−2456 Sockets: 0323−2466
J29 − 4
Run(Wake−up)
J25 −10
PCC 1302 OEM Genset ECM Engine Connection
Auto J25 −11 (Configurable Wake−up)
J29 − 1
PCCNetA(+)
J25−4
J29 − 2
P CC N et B (−)
J25−3
J29 − 3
System Wake−up
J25−5
J28 − 1
HMI FuseB+
J25 −12
J28 − 2
B+Return
J25−8
UseShield ed Twisted Pair forPCCNet Only terminate shield on one end
Configurable Input #3, Coolant Level Switch (Wake −up)
HMI Fused B+ and Customer Fused B+ share acommon 4.5A fuse. HMI FusedB+ is assumedto consume no more than 1.5A
Partnumbers J25 Mate:0323−2445 Sockets: 0323−2466
J25 − Display Fused B+
Manual (Wake−up) J1 − 6 Auto (Config urable Wake−up) J25 −11 J1 − 7 J1 − 1 J1 − 2 J1 − 4
Partnumbers HMI211: 0300−6014
PCC NetA (+)
J25−4
P CC N et B (−)
J25−3
System Wake−up
J1 − 3 J1 − 5
HMI 114 Bargraph Partnumbers HMI114: 0300−???? J1 &J6 Mate: 0323−2011 Sockets: 0323−2466
J11, J25 Harness
J20 Harness
RemoteE−stop PB (B)
Basic Customer
HMI Fuse B+
J25−12
J6 − 2
B+Return
J25−8
Basic Customer
Partnumbers PCC1302: 0327−1617−01
E−stopB+Power
Thesesignals go to the genset but don t go through the PCCcontroller.
(ICRegulator Type/ IC Kubota) Regulator Power Lamp Failed Output
Local
Return
E−stop
PB
J25 − 6
Fused B+ B
Remote E−stopPB (B)
J20 − 10 J20 − 20 J20 − 21
Fused B+
J20 − 2
B+Return
20Amp
+
−
Switched B+
Pilot Relay
E−stopB+ Power
Battery Charger Alternator J20−22 Flash/Failed
J20 − 14
OR
J20 − 15
LSOut
FSO Control
LSOut
Starter Control
LSOut
Switched B+ (Run) Control
Field Flash
E−stopB+ Power
Switched B+
J20 − 3
J20 − 11 Battery Charger Alternator J20 − 22 Flash/Failed RelayB+ internally fusedat1.85A
B.C.Alt. Flash internallyfused at 1.5A
Field Winding
+
J22 − Genset Voltage Partnumbers J11 Mate:0323−2161 Sockets: 0323−2466
Locate near mounting screw chassis.
J20 − 9
E−stopB+ Power
Battery Charging Alternator
Partnumbers J12 Mate:0323−1932 Sockets: 0323−1200
These signals go to the engine but don t go throughthe PCC controller.
J20 − 6
Battery
(Non −ICRegulator Type/ Bosch)
Input (Wake−uponopen) J25 − 2
Return
J20 − 12
Battery Charging Alternator
J12 − Genset Current A
J20 − 1
J20 −18
J20 − 7 Fused B+
J25−4 J25−3 J25−5
J6 − 1
Input
J20 − 4
PCC1302 Baseboard
J25−8
P C C N et A ( + ) P C C N et B (−) SystemWake−up
J20 − 5
J20 − Genset Terminal Block
J25 −12
B+Return
J1 − 3 J1 − 4 J1 − 5
These signals gotothe display but don t g o throughthe PCC controller.
J25−5
HMI Fuse B+
Return
Switches OEM connected OR Terminalblocks for customer connections
Partnumbers J20 Mate:0323−2446 Sockets: 0323−2466
Terminal Block J25 −10
HMI211 Display
No. 630-3270 Sh 1 of 4 Rev. − Sys: ProE Modified 7/2006
J20 − 17
Chassis Ground ConfigurableInput #4, Fuel Level Switch (Wake −up)
OR Local
Input
Driver Rating: 4Amps
Alternator
Peak: 6 Amps
Partnumbers J22Mate: 0323−2226−03
−
J11 − Engine Terminal Block Terminal Block Fused B+
J12 − 1 J20 Harness
L1
L2
L3
LN
J12 − 4 J12 − 2
Fused B+
5A CTs,
J12 − 5 J12 − 3
J11 − 21
Don t connect N inDelta configuration
Pilot Relay
E−stopB+ Power
Keyswitch Control
LS Out
Keyswitch (FSO optionally)
ECM
UseL1/L2/N for1phase applications
(PGI Compliant)
J1939 (+)
J11 − 20
J11 − 19 J11 − 17
120 Ohm
J12 − 6
J22 − 1 J22 − 2 J22 − 3 J22 − 4
J1939 (+) 120ohm terminated
J1939 (−) J1939(Shield)
Only terminate shield ononeend
J1939 (−)
Some ECMsintegrate the FSO withthe Keyswitchoperation. Use adedicated FSO if application s ECM does notprovid e FSO operation.
Usealternatorcentertaps ora transformer ifLL voltage>240 VAC
L−L600 VoltMax
ShuntApplications
J18 − AVR Power Partnumbers J18 Mate:0323−2444 Sockets: 0323−1200
J18 − 1 J18 − 2
10Amp
OR PMG Applications
P2
J18 − 3
PMG (optional)
Partnumbers J17 Mate:0323−2098 Sockets: 0323−1200
J17 − AVR Control
P4 P3 J17 − 2 J17 − 1
FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEEET 1 OF 4 )
J29 −6
HMI2xx or HMI3xx Display
J29 −4
Partnumbers HMI 220: 0300−6314 HMI 320: 0300−6315 J28 Mate: 0323−2091 J29 Mate: 0323−2456 Sockets: 0323−2466
Run (Wake−up)
J29 −1
PCC NetA (+)
J25−4
J29 −2
PCC Net B (−)
J25−3
J29 −3
System Wake−up
J25−5
J28 −1
HMI Fuse B+
J25 −12
J28 −2
B+Return
J25−8
PCC 1302 OEM Genset Hydro−mechanical Engine Connection
HMI211 Display Part numbers HMI211: 0300−6014
J1 − 1 J1 − 2 J1 − 4
J1 − 3 J1 − 5
HMI 112 Bargraph
J1 − 3 J1 − 4 J1 − 5
Part numbers HMI 112: 0300−6050−02 J1& J6 Mate: 0323−2011 Sockets: 0323−2466
PCCNetA (+)
J25−4
PCCNetB( −)
J25−3
System Wake−up
J25−5
HMI Fuse B+
J25 −12
B+Return
J25−8
P C C N et A ( + ) P C C N et B (−) SystemWake−up
Fused B+ These signals go to the display but don tgo throughthe PCC controller.
Remote E−stop PB(B)
HMI FuseB+
J25 −12
J6 − 2
B+Return
J25−8
J 1 1, J 2 5 Harness
Basic Customer
J11 Harness
B+Return
Basic Customer
E−stopB+ Power
PCC1302 Baseboard Partnumbers PCC1302:0327 −1617−01
Fused B+
Return
E−stop
PB
Active Oil PressureSender
Remote E−stopPB(B)
+5V
J11 − 1
Sense
J11 − 3
Return
J11 − 2
Passive Oil PressureSender
Sense
Mag Pick−up
J20 − 21
Fused B+
J20 − 2
B+Return
20Amp
These signals gotothe gensetbut don t go through the PCC controller.
+
−
Pilot Relay
E−stopB+ Power
Lamp Battery Charger J20−22 Failed Alternator Output Flash/Failed
J20 − 14
LSOut
FSO Control
LSOut
Starter Control
LSOut
Switched B+ (Run) Control
E−stopB+ Power
OR
J20 − 15
Battery Charging Alternator
Field Flash
E−stopB+ Power
Switched B+
J20 − 3
J20 − 11 Relay B+in ternally fusedat 1.85A
Battery Charger Alternator J20 − 22 Flash/Failed B.C.Alt. Flash internally fused at 1.5A
Field Winding
+
Driver Rating: 4Amps
Alternator
Peak: 6 Amps
Partnumbers J22Mate:0323 −2226−03
− Terminal Block
J11 − 7
Fused B+
Pilot Relay GlowPlug Control
LS Out
J11 − 2
Input
J11 − 3
Return
J11 − 2
J11 − 7
LS Out
Sense
J11 − 11
J11 − 5
Governor PWM+
Return
J11 − 12
J11 − 4
GovernorPWM −
J11 − 9
J11 − 5
GovernorPWM+
J1 − 2
J11 − 10
J11 − 4
Governor PWM−
J1 − 1
OR
J20 − 20
Switched B+
Terminal Block
RelayB+ internally fusedat 1.85A
Return
Low Oil Pressure Switch
Coolant Temperature Sensor (OnanType)
J11 − 3
J20 − 10
J11 − Engine
J11 − 6 Relay B+
OR
Partnumbers J11 Mate: 0323−2161 Sockets: 0323−2466
Locate near mounting screw chassis.
J20 − 9
J22 − Genset Voltage
These signals gotothe enginebut don t go through the PCC controller.
Fused B+ B
J20 − 6
Battery
(ICRegulator Type/ IC Kubota) Regulator Power
Partnumbers J12 Mate: 0323−1932 Sockets: 0323−1200
J25 −6
Return
J20 − 12
(Non−ICRegulator Type/ Bosch)
Input(Wake−up on open)J25 −2 A
J20 − 1
J20 −18
J20 − 7
J20 Harness
Battery Charging Alternator
J12 − Genset Current
Local
J20 − 5
Input
J20 − 4
Terminal Block
J25−4 J25−3 J25−5
J6 − 1
Return
J20 − Genset
J25 − Display J1 − 6 Auto (Confi gurable Wake−up) J25 −11 J1 − 7
J20 − 17
Switches OEM connected OR Terminalblocks for customer connections
Partnumbers J20 Mate: 0323−2446 Sockets: 0323−2466
Terminal Block
J25 −10
Input
Chassis Ground
Partnumbers J25 Mate: 0323−2445 Sockets: 0323−2466
OR Local
Configurable Input #3, Coolant Level Switch (Wake −up) ConfigurableInput #4, Fuel Level Switch (Wake−up)
HMI Fused B+and CustomerFused B+ share acommon 4.5A fuse. H M I F u se d B + i s assumed to consume nomore than1.5A
UseShieldedTwistedPairfor PCC Net Onlyterminate shieldon one end
Manual(Wake−up)
No. 630-3270 Sh 1 of 4 Rev. − Sys: ProE Modified 7/2006
J25 −10
Auto J25 −11 (Configurable Wake−up)
B+ Return
J12 − 1 J20 Harness
J12 − 4
J20 Harness
J12 − 5
L2
L3 LN 5A CTs,
J12 − 2 J12 − 3 J12 − 6
Don tconnect N inDelta configuration
OR J11 − 6 Relay B+
L1
Ignition Module Control
J22 − 1 UseL1/L2/N for1phase applications
3rd Party FuelActuator Module (20mAMax)
J22 − 2 J22 − 3 J22 − 4
OR + −
Shield
J11 − 8
Fused B+
J 1
J1 − 4
Act. LS Driver
Usealternatorcentertaps ora transformer i f L L v o l ta g e > 2 40 V AC
Fuel Actuator (6 AmpsMax)
−
UseShielded Twisted Pair forMagPU Fused B+
Gov PS Power
J1 − 3
B+Return
Gov PSPower
J1 − 5
G o v P S
AUX 104 GOVERNOR POWER STAGE Partnumbers Aux 104: 0327−1507 J1Mate:0323 −2216: Sockets: 0323−1200
L−L 600VoltMax
ShuntApplications
J18 − AVRPower Partnumbers J18 Mate: 0323−2444 Sockets: 0323−1200
J18 − 1 J18 − 2
10Amp
OR PMG Applications
P2
J18 − 3
PMG (optional)
Partnumbers J17 Mate: 0323−2098 Sockets: 0323−1200
J17 − AVR Control
P4 P3 J17 − 2 J17 − 1
FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEET 2 OF 4 )
I n p ut # 3 I n p ut # 4 Input #5 Sense Oil Temperature RTD Sensor
J11 − 5
J11 − 7
Current source J10 − 3 Current return
J10 − 9 J11 − 6
Sense return
J11 − 9 J10 − 5
J10 − 6
J10 − 11
J10 − 12
J11 − 8
J11 − 10
J11 − 12
J11 − 3
Return
J11 − 2
J11 − 4
OR
Return
OR
Gnd must be wire d in
OR
DiscreteInput(Sense)
AND/ OR I n p u t# 7
Current source 0−38VAnalog Input
Sense return
OR
Sense Sense return
Gnd must be wiredin
OR
DiscreteInput (Sense)
Gnd must be wiredin
Sense
J11 − 13
J11 − 15
Return
J11 − 14
J11 − 16
DiscreteInput (Sense)
Discrete Input (Sense)
AND /OR
SystemWake−up TB15 − 5 PCC Net A(+) TB1 −1 J29 − 2 PCCNetB (−) TB1 −2 J28 − 1 CustomerFused B+ TB1 −5 J28 − 2 B+Return TB1 −3
TB1 −1 PCCNetB (−) TB1 −2 CustomerFused B+ TB1 −5
J1−5 J1−3 J1−4
Partnumbers w/oenclosure: 300 −5929−01 w/enclosure: 300 −5929−02
OR
TB15 − 5
PCC Net A(+)
HMI 113 Annunciator
Return
J6−1 J6−2
J2−3
B+Return
TB1 −3
SystemWake−up
TB15 − 5
PCC Net A(+)
TB1 −1
PCCNet must use a daisy chain topology only
PCCNetB (−) TB1 −2 CustomerFused B+ TB1 −5 B+Return TB1 −3
PCC Net A(+)
UseShieldedTwisted Pairfor PCC Net Onlyterminateshieldon one end,to prevent groundloops
AND /OR
PCC1302 Baseboard
Usea local,floating(non−grounded) DCpowersupplyifB+ linehashigh resistance(>1 ohm)due tolong runs, toprevent brief poweroutages during genset starts
TB1 −1
PCCNetB (−) TB1 −2 J2−4 TB1 −16 CustomerFused B+ TB1 −5 B+Return TB1 −3 TB1 −15
Refer to the PCCNetSpec Sheet for further detailson PCCNet
TB 1
AND
J11 /OR J10 J4 J3 J2
Return
AND /OR
OR
PCC Net Devices
TB1 − 3
J29 − 1
Partnumbers HMI 112:0300−6050−02
Return
OR
Discrete Input (Sense)
I n p ut # 8
Customer Fused B+
Return Customer Fused B+
B+Return
J29 − 3
HMI 112 Bargraph
OR
Current return
PCC Net B (−)
No. 630-3270 Sh 1 of 4 Rev. − Sys: ProE Modified 7/2006
CustomerFused B+ TB1 − 5
Return
Sense return Sense
TB1 − 1 TB1 − 2
SystemWake−up
Current return
PCC 1302 Customer Connections:
TB15 − 5
PCC NetA (+)
Battery Charger
Customer Fused B+
Current source
0 −5VAnalog Input
OR
Discrete Input (Sense)
Gnd must be wire d in
TB1−10
System Wake−up
J1 − 4 J1 − 1 J1 − 2 J1 − 3 J1 − 5
HMI2xx and HMI3xx Display
Sense return
Sense return
Intake Manifold Temperature RTD Sensor
HMI211 Part numbers HMI211: 0300−6014
Current return
RemoteStart
J1 − 7
Remote
OR
Sense
Gnd must be wiredin
I n pu t # 2
J11 − 1
Current return
Current source
FuelLevel Sensor RTD Sensor
Gnd must be wiredin
+/ −5V Analog Input
Current source
Sense Ambient Temperature RTD Sensor
J11 − 11
J10 − 4 J10 − 10
Sense Exhaust Stack Temperature #1 RTD Sensor
I n pu t # 1 Sense
Input #6
Aux 101 J1 −5 Remote I/O J1 −3 J1 − 4 Part numbers Aux 101: 0327−1536
J14 − 1 J14 − 2
System Wake−up TB15 − 5 PCCNetA (+) PCCNetB( −)
TB1 − 1 TB1 − 2
TB 15
CustomerFused B+ TB1 − 5 B+Return TB1 − 3
Mounting screw J5
Chassis Ground
J6 J2 − 1
Relay NO
J2 − 2
Relay Com
J2 − 3
RelayNC
J2 − 4
Relay NO
J2 − 5 J2 − 6
Relay Com Relay NC
J2 − 7 J2 − 8
Relay Com
J2 − 9
Relay NC
Relay NO
J2 − 10
Relay NO
J2 − 11
Relay Com
J2 − 12
Relay NC
J3 − 1
Relay NO
J3 − 2
Relay Com
J3 − 3
Relay NC
J3 − 4
Relay NO
J3 − 5
Relay Com
J3 − 6
Relay NC
Aux 101 Relay 1 Output Aux 101 Relay 2 Output Aux 101 Relay 3 Output Aux 101 Relay 4 Output
Aux 101 Relay 5 Output Aux 101 Relay 6 Output
J10 J10 − 7
+
J10 − 9
Return
J10 −8
+
J10 − 10
Return
Maximum of 2Aux 101 & 102’s can be used per genset
Relay NO
J4 − 2
Relay Com
J4 − 4
Relay NO
5VDCSupply #2 (20 mAmax)
J4 − 5
Relay Com
J4 − 6
RelayNC
J4 − 3
Relay NC
Aux 101 Relay 7 Output Aux 101 Relay8 Output
Part numbers Aux 102: 0327−1265
Input #9
Input #10
Input #12
Input
J4 − 1
Return
J4 − 2
J2 J3
Aux 101 Relay Output Ratings: 30VDC, 250VAC NO: 5A NC: 3A
Input #11 J4 − 1
5VDCSupply#1 (20mA max)
Aux 102 Remote I/O
J1
J 4
J1 − 1
Relay NO
J2 − 1 J3 − 1
Relay Com
J1 − 2 J2 − 2
Relay NO Relay Com
J3 − 2
Relay NC
RelayNC
J1 − 3
Relay NO
J2 − 3
Relay Com
J3 − 3
Relay NC
J1 − 4
Relay NO
J2 − 4
Relay Com
J3 − 4
RelayNC
J1 − 5
Relay NO
J2 − 5
Relay Com
J3 − 5
Relay NC
J1 − 6
Relay NO
J2 − 6
Relay Com
J3 − 6
RelayNC
J4 − 5
J1 − 7
Relay NO
J4 − 6
J2 − 7
Relay Com
Input
J4 − 3
Return
J4 − 4
Input Return Input
J4 − 7
Return
J4 − 8
J3 − 7
RelayNC
J1 − 8
Relay NO
J2 − 8
Relay Com
J3 − 8
Relay NC
Aux 102 Relay 9 Output Aux 102 Relay 10 Output Aux 102 Relay 11 Output Aux 102 Relay 12 Output
Aux 102 Relay Output Ratings: 2A, 30VDC, 250VAC
Partnumbers Aux 101 mates: J 1 : 0 3 2 3−2192−04 J14:0323−1678−02 Others: comew/ board Aux 102 mates: J1, J2, J3:0323−1678−08 J4: 0323−1678−07 Others: comew/ board
Aux 102 Relay13 Output Aux 102 Relay14 Output Aux 102 Relay15 Output Aux 102 Relay16 Output
FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEEET 3 OF 4 )
