You are on page 1of 15

Instruction Sheet

C698 3-2006

Installation and Setup Instructions for I/O Module Kit 5411320


This instruction sheet describes the installation Base I/O Module (AUX101)
and configuration of an I/O Module on gensets with
a PCC2100 control. This Instruction Sheet pro- The PowerCommandR AUX101 I/O Module (see
Figure 1) includes the following.
vides information on how to install the I/O Module
kit and provides control configuration information S Eight discrete Form-C relay output sets
for gensets that already have the I/O Module used to control system equipment. Each
installed. relay includes a status LED (DS3 thru
DS10).
INTRODUCTION S Inputs 1 and 2 can be configured for voltage
and speed bias as a means to match the
The PowerCommand I/O Module is an option that voltage and frequency of the generators
can be used on generator sets with a PCC2100 prior to the control being set up for active
control. The I/O Module can be used in a 12 or 24 droop paralleling operation.
VDC system.
S Two 5 VDC voltage sources to be used with
The PCC2100 control, starting with software ver- active senders.
sion 2.500, supports up to two Base I/O Modules
and two Expansion I/O Modules. S Two network status LEDs.
DS1 (green) indicates the AUX101 is
If your installation includes both the Base I/O Mod- connected to the network and is operat-
ule (AUX101) and the optional Expansion I/O Mod- ing normally.
ule (AUX102), sixteen relay outputs and two dis- DS2 (red) indicates the AUX101 has
crete analog inputs are available for auxiliary con- lost it connection or is not connected to
trol and monitoring of the power system. the network.

Relay outputs can be used for controlling equip- S One device number indicator (U16) that is
ment such as motors, louvers, fans, and pumps. used to uniquely identify an I/O Module
The relays can be configured individually by using when more than one AUX101 is included on
InPower software. the same network.

PowerCommand is a registered trademark of Cummins Inc. Page 1 of 15


Since the AUX101 does not require any special TABLE 1. AUX101 CONNECTORS
configuration, it can be used immediately. It in-
cludes the following default settings: Connector Pins Description

S All inputs are disabled except for the two J1 5 Connection to 1301 control
analog inputs J2 12 Dry contact outputs 1 4
S Outputs are mapped as follows: J3 6 Dry contact outputs 5 6
1 Low Oil Pressure J4 6 Dry contact outputs 7 8
2 High Engine Temperature J5 20 AUX102 connection
3 Not Defined
J6 6 Not used
4 Battery (Low, Weak, or High)
5 Overspeed J7 6 Not used
6 Fail to Start J10 12 GND, 5V sources, current
7 Not In Auto sources
8 Run J11 16 Analog/Digital inputs 1 8
The I/O Module includes the connectors listed in J14 2 Connection to power
Table 1. source

J11 J10

DEVICE
NUMBER
INDICATOR

S1
J14 (DEV#)

J1

J5

DS1

DS2

J2 J3 J4

FIGURE 1. BASE I/O MODULE (AUX101)


C698
Page 2 of 15
EXPANSION I/O MODULE (AUX102) A ribbon cable is used to connect the Expansion
I/O Module to the Base I/O Module. The AUX102
includes the following default settings:
The PowerCommandR AUX102 is an Expansion
I/O Module (see Figure 2). If your installation is to S All inputs are disabled
include an AUX102, your must purchase kit
5410772. S Outputs are mapped as follows:
9 Pre-Low Oil Pressure
10 Pre-High Engine Temperature
The AUX102 Expansion I/O Module includes the
following. 11 Not Defined
12 Not Defined
13 Low Engine Temperature
S Eight Form-C relay output sets used to con- 14 Not Defined
trol system equipment. Each relay includes 15 Not Defined
a status LED (DS1 thru DS8). 16 Not Defined

J4 (CUSTOMER INPUTS) MOUNTING SCREW AND


LOCK WASHER (NOT
INCLUDED IN THIS KIT)

J5 RING
EIGHT FORM-C TERMINAL
RELAY CONTACTS

J6
J3

J2

J1

FIGURE 2. EXPANSION I/O MODULE (AUX102)

C698
Page 3 of 15
INSTALLATION WARNING AC voltages and currents present
an electrical shock hazard that can cause se-
The following parts are included in the I/O Module vere personal injury or death. Incorrect instal-
kit. lation, service, or parts replacement can result
in severe personal injury, death, and/or equip-
Description Qty ment damage.
I/O Module 1 CAUTION If present, always disconnect a
Connector (2 Pin) 1 battery charger from its AC source before dis-
Connector (5 Pin) 1 connecting the battery cables. Otherwise, dis-
connecting the cables can result in voltage
spikes high enough to damage the DC control
The following part is not included in the I/O Module circuits of the generator set.
kit but may be needed for your installation.
WARNING Accidental starting of the genera-
Description Part Number tor set while working on it can cause severe
Expansion I/O Module 5410772 personal injury or death. Prevent accidental
starting by disconnecting the starting battery
cables (negative [] first).
Read these instructions completely and become
familiar with safety warnings, cautions, and proce- Make certain the battery area has been well-
dures before starting the installation. ventilated before servicing the batteryWear
gogglesStop the genset and disconnect the
Mounting Guidelines charger before disconnecting battery cables.
Arcing can ignite explosive hydrogen gas giv-
The I/O Module is suitable for non-engine panel en off by batteries, causing severe personal in-
mounting within an enclosure. As such, it should jury. Arcing can occur when a cable is removed
not be directly mounted on the engine. or re-attached, or when the negative () battery
cable is connected and a tool used to connect
or disconnect the positive (+) battery cable
To prevent the I/O Module from being exposed to
touches the frame or other grounded metal
conditions beyond its specifications, care should
part of the generator set. Always remove the
be taken not to mount it close to the engine exhaust
negative () cable first, and reconnect it last.
pipes. Avoid mounting the Module(s) in a manner
Make certain hydrogen from the battery, en-
that would expose them to direct sunlight or rain/
gine fuel, and other explosive fumes are fully
snow.
dissipated. This is especially important if the
battery has been connected to a battery char-
Choose a clean, vibration-free mounting surface. ger.
Avoid locations that are hot, damp, or dusty or that
are close to EMI sources. The AUX101 and WARNING Ignition of explosive battery gases
AUX102 are designed for proper operation in can cause severe personal injury or death.
ambient temperatures from 40 to +60 Degrees C Arcing at battery terminals, light switch or oth-
(40 to 140 Degrees F), and for storage from 40 er equipment, flame, pilot lights and sparks
to +80 Degrees C (40 to 176 Degrees F). The can ignite battery gas. Do not smoke, or switch
modules are designed to operate with humidity up trouble light ON or OFF near a battery. Dis-
to 95%, non-condensing. charge static electricity from body before
touching batteries by first touching a
grounded metal surface.
Physical Installation
Refer to the PCC2100 Control wiring diagram
WARNING Incorrect installation, service, or (Figure 12) when connecting the I/O Module to the
replacement of parts can result in severe per- PCC2100 control. This wiring diagram also in-
sonal injury or death and/or equipment dam- cludes information on wiring items (annunciator
age. Only trained and experienced personnel and governor power module) not included in this
are to perform the following procedures. kit.
C698
Page 4 of 15
Refer to the I/O Module wiring diagram (Figure not include necessary clearance for wire con-
11) when connecting the I/O Module to other nections.
equipment.
3. If included in your installation, use M4 hard-
NOTE: Mounting hardware for the I/O Module is ware to mount the Expansion I/O Module (kit
not included in this kit. The instructions be- 5410772) near the Base I/O Module and plug
low include suggested hardware sizes. the Expansion I/O Modules J6 connector into
the Base I/O Modules J5 connector. Be sure
1. Make sure the generator set is shut down and to use a screw and lock washer to ground the
disabled: J5 ring terminal.
4. Select appropriate wire and connect wiring
a. The PCC2100 is in the Off mode. from the PCC2100 baseboard TB1 connector
b. The generator set Run/Off/Auto switch is to the enclosed 5-pin connector (see Figure
in the Off position and the generator is 12). Plug the connector into the J1 connector
cool (to the touch). on the AUX101.

c. The battery charger (if equipped) is 5. Connect any system equipment to the dry
turned off and disconnected. contact output connectors on the AUX101 (J2,
J3, and J4) and, if installed, the AUX102 (J1,
d. The negative () cable from the battery is J2, and J3).
disconnected to prevent accidental start-
6. Make connections for any analog/discrete in-
ing.
puts to the J11 connector on the AUX101 and,
if installed, the J4 connector on the AUX102.
2. Select a suitable location and mount the I/O
Module using M4 hardware. Figure 3 shows 7. If needed, connect GND, 5V sources, and cur-
the Module dimensions (including the Expan- rent sources to the J10 connector on the
sion I/O Module). The outside dimensions do AUX101.

0.51 (13) 5.31 (135) DIMENSIONS SHOWN


4.53 (115) 0.39 (10) IN INCHES (mm)
0.47 (12)

2.95 (75) 0.51 (13)


2.17 (55) 0.47 (12)

5.9
(150)
5.12 3.94
(130) BASE I/O MODULE (100)
EXPANSION
0.25 3.15 I/O MODULE
(6) (80)
B B

1.25 MIN (32)


2.5 MAX (63)
0.39 (10)

0.23 (5.9) 0.23 (5.9)


SECTION A-A SECTION B-B

FIGURE 3. I/O MODULE FOOTPRINT


C698
Page 5 of 15
8. Select appropriate wire for power connections a. Connect the negative () cable to the bat-
and install wiring on the enclosed 2-pin con- tery.
nector. Connect the wiring to the power
b. Reconnect the battery charger (if used).
source (PCC2100 TB2-3 = B+ and TB2-4 =
B/GND see Figure 4) and plug the connec- c. Place the Run/Off/Auto switch to the de-
tor into the J14 connector on the AUX101. sired position.
9. Reconnect the genset as follows. d. Set the PCC2100 to the desired mode.

TO PCCNET
DEVICES

DEFAULT SETTING
TB1-CUSTOMER FAULTS:
1 CUSTOMER FAULT 1
2 GROUND FAULT
3 LOW FUEL
4 RUPTURE BASIN FAULT
TB1-CUSTOMER RELAYS:
1 COMMON WARNING
2 COMMON SHUTDOWN
3 NOT IN AUTO
4 READY TO LOAD

FIGURE 4. PCC2100 CONTROL WIRING CONNECTIONS


C698
Page 6 of 15
10. Verify that the DS1 LED on the AUX101 is NOTE: The PCC2100 genset control current-
green and that all devices are powered. ly supports up to two AUX101s. If you
are using the speed/voltage bias in-
11. If your installation includes only one AUX101, puts on an AUX101, the device num-
the device number displayed on the module is ber on that AUX101 must be set to 0.
0 (see Figure 1). If your installation includes
more than one AUX101,
12. Configure the I/O Module(s), as described in
a. Press and hold the S1 (DEV#) button for the following pages.
a least five seconds, until a small dot ap-
pears next to the number displayed on I/O MODULE CONFIGURATION
the device number indicator.
b. To change the device number, press and The I/O Module can only be configured using the
release S1 until the desired number is PC service tool.
displayed. After five seconds of inactivity,
the new device number is set and the
The AUX101 is a plug and play device. Once con-
small dot will go out.
nected to the PCCNet network, the PCC2100
c. After the device number has been should recognize it there. Up to two AUX101s can
changed, cycle power from the I/O Mod- be connected to a PCC2100. The user can disable
ule by unplugging and replugging the J14 an AUX101 by changing the AUX101(s) Enable
connector. setting to Disable (see Figure 5).

FIGURE 5. DISABLING THE I/O MODULE(S)


C698
Page 7 of 15
Although the AUX101 is designed for twelve net- input. It can only be used as a voltage bias input.
work inputs, only two of the inputs can currently be This feature must be enabled by changing the Volt-
used with the PCC2100 control. If more than one age Bias Enable value to Enable.
AUX101 is connected to a PCC2100, speed and
voltage bias will only function on the device with Input 2 of the AUX101 is set up as a Speed Bias
the device number set to 0. input. It can only be used as a speed bias input.
This feature must be enabled by changing the
Input 1 of the AUX101 is set up as a Voltage Bias Speed Bias Enable value to Enable.

FIGURE 6. VOLTAGE AND SPEED BIAS ENABLE

C698
Page 8 of 15
The Voltage Bias input has a range of 3V to +3V, values that correspond to the AUX101 input volt-
with 0V input corresponding to 0 voltage bias. The ages. For example, if the Speed Bias scale is set to
Speed Bias has a range of 0V to 5V with 2.5V input 200 RPMs, a 5V input into the AUX101 changes
corresponding to 0 speed bias. the speed reference +200 RPMs. A 0V input into
Both inputs have a Scale parameter which sets the AUX101 changes the speed reference 200
up the minimum and maximum voltage or RPM RPMs. The Voltage Bias Scale acts the same way.

FIGURE 7. SPEED BIAS SCALE

C698
Page 9 of 15
All of the available relay outputs are supported with AUX102 expansion board is installed. Although
the PCC2100. Outputs 18 are available with the each output has a default fault assigned to it, they
AUX101 and outputs 916 are available if the can be changed using the menu shown below.

FIGURE 8. OUTPUT FAULT MENU FOR AUX101 DEVICE #1

C698
Page 10 of 15
Figure 9 shows the menu that can be used to
change the output values if a second AUX101 and
AUX102 are installed.

FIGURE 9. OUTPUT FAULT MENU FOR AUX101 DEVICE #2

C698
Page 11 of 15
The monitoring screen shown in Figure 10 display- board is installed and it shows the voltage and
s information about the AUX101 devices con- speed bias values based on the Scale value.
nected to the PCC2100. It shows if an expansion

FIGURE 10. AUX101 MONITORING SCREEN

C698
Page 12 of 15
No. 630-3142 Sh 1 of 2
Rev. A Sys: HP
Modified 7/2005

FIGURE 11. I/O MODULE WIRING DIAGRAM


C698
Page 13 of 15
No. 630-3142 Sh 2 of 2
Rev. A Sys: HP
Modified 7/2005

FIGURE 11. I/O MODULE WIRING DIAGRAM


C698
Page 14 of 15
No. 612-6764 Sh 1 of 2
Rev. E Mod Sys: HP
Modified 1/2006

FIGURE 12. PCC2100 CONTROL WIRING


DIAGRAM
C698
Page 15 of 15