Aux101 Service Manual
Aux101 Service Manual
Owner Manual
Owner
Controller
AUX 101
AUX 102
English
Original Instructions 5-2015 A030K737 (Issue 6)
Table of Contents
2. INTRODUCTION............................................................................................................................ 5
2.1 About This Manual.................................................................................................................. 5
2.2 AUX101................................................................................................................................... 5
2.2.1 AUX101 Inputs and Outputs ........................................................................................ 5
2.2.2 AUX101 Inputs............................................................................................................. 5
2.2.3 AUX101 Outputs .......................................................................................................... 5
2.3 AUX102................................................................................................................................... 5
2.3.1 AUX102 Inputs and Outputs ........................................................................................ 6
2.3.2 AUX102 Inputs............................................................................................................. 6
2.3.3 AUX102 Outputs .......................................................................................................... 6
2.4 Numbering of AUX102 Inputs and Outputs ............................................................................ 6
4. HARDWARE ................................................................................................................................ 19
A030K737 (Issue 6) i
5. CONFIGURATION OF THE AUX 101 AND AUX 102 WITH VARIOUS CONTROLLERS ......... 41
5.1 Tools to Configure a PCC 1301 or PowerCommand 1.x AUX 101/102 ............................... 41
5.1.1 About the I/O Module Menus ..................................................................................... 41
5.1.2 Using InPower to Configure the AUX 101 and AUX 102........................................... 46
5.2 Tools to Configure a PCC 2100 AUX 101/102 ..................................................................... 46
5.2.1 How to Disable or Enable an AUX 101 on the PCC 2100......................................... 46
5.2.2 How to Configure a Switch on the PCC 2100............................................................ 46
5.2.3 How to Configure a Voltage Bias on a PCC 2100..................................................... 46
5.2.4 How to Configure a Speed Bias on a PCC 2100....................................................... 47
5.2.5 How to Configure an Output on a PCC 2100 ............................................................ 47
5.3 Tools to Configure a PowerCommand 2.x or 3.x AUX101/102 ............................................ 47
5.3.1 How to Find the AUX101 Setup Screens in the Operator Panel ............................... 47
5.3.2 How to Configure a Switch on the PowerCommand 2.x or 3.x ................................. 48
5.3.3 How to Configure an Additional Function for AUX101 Inputs on the
PowerCommand 2.x or 3.x .......................................................................................... 48
5.3.4 How to Configure an Analog Input on the PowerCommand 2.x or 3.x...................... 48
5.3.5 How to Configure an Output on the PowerCommand 2.x or 3.x ............................... 49
6. CONFIGURING THE AUX 101 AND AUX 102 WITH THE MCM3320........................................ 51
6.1 Supplementary Interface Device (SID) ................................................................................. 51
6.1.1 Generator Sets by SID............................................................................................... 51
6.1.2 Loads by SID ............................................................................................................. 51
6.1.3 SID Required.............................................................................................................. 51
6.1.4 Legacy SID Override (Before V2.00) ......................................................................... 52
6.1.5 Compatible Software Versions (AUX 101)................................................................. 52
ii A030K737 (Issue 6)
7. CONFIGURING THE AUX 101 AND AUX 102 WITH THE PC500/550 ...................................... 67
7.1 Configuring Modbus Communication Parameters ................................................................ 67
7.2 AUX101 Board ...................................................................................................................... 68
7.3 AUX 101 S1 Device Number ................................................................................................ 68
7.4 Configuring AUX 101 Using PC500/550 User Interface....................................................... 69
7.5 I/O Control Capabilities Over Modbus .................................................................................. 69
8. TROUBLESHOOTING ................................................................................................................. 71
8.1 DS1 and DS2 Are Off ........................................................................................................... 71
8.1.1 Checking the Power Connections.............................................................................. 71
8.1.2 Checking the Wires.................................................................................................... 71
8.1.3 Checking the Power Supply....................................................................................... 71
8.2 DS2 Is On ............................................................................................................................. 71
8.2.1 Checking the PCCNet Connections........................................................................... 71
8.2.2 Checking the Wires.................................................................................................... 71
8.2.3 Checking the Device to Which the Board Is Connected............................................ 71
9. MANUFACTURING FACILITIES.................................................................................................. 73
iv A030K737 (Issue 6)
1 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.
A030K737 (Issue 6) 1
2 A030K737 (Issue 6)
A030K737 (Issue 6) 3
4 A030K737 (Issue 6)
2 Introduction
2.2 AUX101
The PowerCommand AUX101 provides additional inputs and additional outputs for auxiliary
control and monitoring of the power system.
Description Value
Number of Inputs 8
Number of Outputs 8
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.
A030K737 (Issue 6) 5
2. Introduction 5-2015
Description Value
Number of Inputs 4
Number of Outputs 8
6 A030K737 (Issue 6)
Description Value
Maximum Number of AUX 101 2
Maximum Number of AUX 102 2
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.
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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
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.
3.1.3 Possible Functions 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
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
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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 Functions of AUX 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
3.1.5 Possible Functions 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
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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
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
3.1.6 Default Functions of AUX 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
* - 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.
Description Value
Maximum Number of AUX 101 2*
Maximum Number of AUX 102 2*
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5-2015 3. Characteristics of the AUX 101 and AUX 102 with Various Controllers
* - The PCC 2100 does not support any additional inputs on the second AUX 101 or second
AUX 102. It only supports the additional outputs.
TABLE 12. POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR PCC 2100
3.2.3 Default Functions of AUX 101 Outputs with the PCC 2100
TABLE 13. DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE PCC 2100
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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
TABLE 14. POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR PCC 2100
3.2.5 Default Functions of AUX 102 Outputs with the PCC 2100
TABLE 15. DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE PCC 2100
Description Value
Maximum Number of AUX101 2
Maximum Number of AUX102 2
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5-2015 3. Characteristics of the AUX 101 and AUX 102 with Various Controllers
NOTICE
PCC2300 base board 0327-1636 does not support the AUX101.
3.3.3.1 Default Functi ons o f AUX101 Inpu ts for PowerCommand 2.x and
3.x
All AUX101 inputs are disabled.
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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
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 .
NOTICE
Masterless Load Demand Enable Switch and Predictive Load Enable Switch are not available yet.
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5-2015 3. Characteristics of the AUX 101 and AUX 102 with Various Controllers
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.
A030K737 (Issue 6) 15
3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
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.
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5-2015 3. Characteristics of the AUX 101 and AUX 102 with Various Controllers
8 2627 2889
3.3.5.1 Default Functi ons o f AUX102 Inpu ts for PowerCommand 2.x and
3.x
All AUX102 inputs are disabled.
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3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 5-2015
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4 Hardware
4.1.1 AUX101 S1
The S1 button can be used to change the AUX101 device number.
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4. Hardware 5-2015
Co nn ec to r 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
FIGURE 2. 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
4.1.4.2 AUX101 J2
FIGURE 3. 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 AUX101 output 2, normally-open contact
J2-5 AUX101 output 2, common contact
J2-6 AUX101 output 2, normally-closed contact
J2-7 AUX101 output 3, normally-open contact
J2-8 AUX101 output 3, common contact
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4. Hardware 5-2015
Pin Description
J2-9 AUX101 output 3, normally-closed contact
J2-10 AUX101 output 4, normally-open contact
J2-11 AUX101 output 4, common contact
J2-12 AUX101 output 4, normally-closed contact
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
FIGURE 4. AUX101 J3
Pin Description
J3-1 AUX101 output 5, normally-open contact
J3-2 AUX101 output 5, common contact
J3-3 AUX101 output 5, normally-closed contact
J3-4 AUX101 output 6, normally-open contact
J3-5 AUX101 output 6, common contact
J3-6 AUX101 output 6, normally-closed contact
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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
4.1.4.4 AUX101 J4
FIGURE 5. AUX101 J4
Pin Description
J4-1 AUX101 output 7, normally-open contact
J4-2 AUX101 output 7, common contact
J4-3 AUX101 output 7, normally-closed contact
J4-4 AUX101 output 8, normally-open contact
J4-5 AUX101 output 8, common contact
J4-6 AUX101 output 8, normally-closed contact
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
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4. Hardware 5-2015
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.
Pin 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 Ground for current source or voltage source
J10-11 Ground for current source or voltage source
J10-12 Ground for current source or voltage source
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Description Value
Maximum Output Current 20 mA
Description Value
Output Voltage 5 VDC
Maximum Output Current 20 mA
Pin Description
J11-1 AUX101 input 1, reference input
J11-2 AUX101 input 1, switch input
J11-3 AUX101 input 2, reference input
J11-4 AUX101 input 2, switch input
J11-5 AUX101 input 3, reference input
J11-6 AUX101 input 3, switch input
J11-7 AUX101 input 4, reference input
J11-8 AUX101 input 4, switch input
J11-9 AUX101 input 5, reference input
J11-10 AUX101 input 5, switch input
J11-11 AUX101 input 6, reference input
J11-12 AUX101 input 6, switch input
J11-13 AUX101 input 7, reference input
J11-14 AUX101 input 7, switch input
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4. Hardware 5-2015
Pin Description
J11-15 AUX101 input 8, reference input
J11-16 AUX101 input 8, switch input
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
Maximum Input Voltage 24 VDC
Differential Voltage Range 0~5 VDC
Description Value
Input Type Discrete or analog
Maximum Input Voltage 40 VDC
Differential Voltage Range 0~38 VDC
Pin Description
J14-1 Input power B+
J14-2 Input power B-
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5-2015 4. Hardware
Description Value
Input Voltage 5-40 VDC
Operating Voltage 12 VDC or 24 VDC
Current Consumption 900 mA (12 VDC)
450 mA (24 VDC)
Indicator Description
DS1 This is on if AUX102 output 9 is active.
DS2 This is on if AUX102 output 10 is active.
DS3 This is on if AUX102 output 11 is active.
DS4 This is on if AUX102 output 12 is active.
DS5 This is on if AUX102 output 13 is active.
DS6 This is on if AUX102 output 14 is active.
DS7 This is on if AUX102 output 15 is active.
A030K737 (Issue 6) 27
4. Hardware 5-2015
Connector 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 Description
J1-1 AUX102 output 9, normally-open contact
J1-2 AUX102 output 10, normally-open contact
J1-3 AUX102 output 11, normally-open contact
J1-4 AUX102 output 12, normally-open contact
J1-5 AUX102 output 13, normally-open contact
J1-6 AUX102 output 14, normally-open contact
J1-7 AUX102 output 15, normally-open contact
J1-8 AUX102 output 16, normally-open contact
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5-2015 4. Hardware
4.2.2.2 AUX102 J2
Pin Description
J2-1 AUX102 output 9, common contact
J2-2 AUX102 output 10, common contact
J2-3 AUX102 output 11, common contact
J2-4 AUX102 output 12, common contact
J2-5 AUX102 output 13, common contact
J2-6 AUX102 output 14, common contact
J2-7 AUX102 output 15, common contact
J2-8 AUX102 output 16, common contact
4.2.2.3 AUX102 J3
Pin Description
J3-1 AUX102 output 9, normally-closed contact
J3-2 AUX102 output 10, normally-closed contact
J3-3 AUX102 output 11, normally-closed contact
J3-4 AUX102 output 12, normally-closed contact
J3-5 AUX102 output 13, normally-closed contact
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4. Hardware 5-2015
Pin Description
J3-6 AUX102 output 14, normally-closed contact
J3-7 AUX102 output 15, normally-closed contact
J3-8 AUX102 output 16, normally-closed contact
4.2.2.4 AUX102 J4
Pin Description
J4-1 AUX102 input 9, switch input
J4-2 AUX102 input 9, reference input
J4-3 AUX102 input 10, switch input
J4-4 AUX102 input 10, reference input
J4-5 AUX102 input 11, switch input
J4-6 AUX102 input 11, reference input
J4-7 AUX102 input 12, switch input
J4-8 AUX102 input 12, reference input
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.
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5-2015 4. Hardware
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.
A030K737 (Issue 6) 31
4. Hardware 5-2015
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.
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5-2015 4. Hardware
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
NOTICE
The outside dimensions do not i nclude necessary clearance for wire connections.
A030K737 (Issue 6) 33
4. Hardware 5-2015
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
Input Pins
9 J4-1, J4-2
10 J4-3, J4-4
11 J4-5, J4-6
12 J4-7, J4-8
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
Output Pins
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5-2015 4. Hardware
NOTICE
Input pin is grounded.
A030K737 (Issue 6) 35
4. Hardware 5-2015
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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.
FIGURE 20. EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH ONE POWER SUPPLY
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4. Hardware 5-2015
FIGURE 21. EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH TWO POWER SUPPLIES
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5-2015 4. Hardware
A030K737 (Issue 6) 39
4. Hardware 5-2015
40 A030K737 (Issue 6)
NOTICE
For some settings, InPower has more options than the operator panel. If you use
InPower to select an option that is not available in the operator panel, the operator
panel di splays " N/A".
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.
A030K737 (Issue 6) 41
5. Configuration of the AUX 101 and AUX 102 with Various Controllers 5-2015
5.1.1.1 How to Find t he I/O Module Menu in the PCC 1301 Operator Panel
FIGURE 23. HOW TO FIND THE I/O MODULE MENU IN THE PCC 1301 OPERATOR PANEL
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5-2015 5. Configuration of the AUX 101 and AUX 102 with Various Controllers
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.
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.
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5. Configuration of the AUX 101 and AUX 102 with Various Controllers 5-2015
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.
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.
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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.
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.
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5. Configuration of the AUX 101 and AUX 102 with Various Controllers 5-2015
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.
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For a voltage bias connected to two power supplies, skip this step.
8. Save your changes in InPower.
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5. Configuration of the AUX 101 and AUX 102 with Various Controllers 5-2015
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.
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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.
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5. Configuration of the AUX 101 and AUX 102 with Various Controllers 5-2015
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SID Loads
SID0 1-6
SID1 7-10
SID2 11-14
SID3 15-18
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6. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
• 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.
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. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
6.2.1 AUX101 S1
The S1 button can be used to change the AUX101 device number.
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6. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
6.2.7 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
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6. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
6.2.11 AUX101 J5
If the AUX101 is connected to an AUX102, this is connected to J6 on the AUX102.
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6. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
Pin Description
J14-1 Input power B+
J14-2 Input power B-
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6. Configuring the AUX 101 and AUX 102 with the MCM3320 5-2015
6.3.7 AUX102 J5
J5 is connected to a good earth ground.
6.3.8 AUX102 J6
This is connected to J5 on the AUX101.
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7. Configuring the AUX 101 and AUX 102 with the PC500/550 5-2015
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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.
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.
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7. Configuring the AUX 101 and AUX 102 with the PC500/550 5-2015
Refer to Modbus Register Mapping (A029X159) for additional information about the Modbus
registers.
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8 Troubleshooting
8.2 DS2 Is On
DS2 is on, but the board should be connected to a PCCNet network.
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8. Troubleshooting 5-2015
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9 Manufacturing Facilities
NORTH AMERICA EMEA, CIS ASIA PACIFIC
Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited
1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis, MN 55432 USA Manston Park TT International Tradepark
Manston, Ramsgate Singapore 608838
Kent CT12 5BF
United Kingdom
Phone +1 763 574 5000 Phone +44 1843 255000 Phone +65 6417 2388
Toll Free +1 800 888 6626 Fax +44 1843 255902 Fax +65 6417 2399
Fax +1 763 574 5298
A030K737 (Issue 6) 73
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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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FIGURE 43. PCC 1302/POWERCOMMAND 1.X AND AUX 101/102, 0630-3440, SHEET 1 OF 2
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power.cummins.com
Copyright © 2015 Cummins Power Generation Inc. All rights reserved.
Cummins Power Generation, the "C" logo, and Cummins are registered
trademarks of Cummins Inc. PowerCommand, AmpSentry, InPower and "Our
energy working for you." are trademarks of Cummins Power Generation.
Other company, product, or service names may be trademarks or service
marks of others. Specifications are subject to change without notice.