Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 1 of 17

Subject : Introduction of AUX 101 (add on Module to PCC 2100 Genset Controls) to enable theControl for Parallel application.

Ref. No. :

FESN :

Application Group : G-drive

Date : December, 2006

No. : 3242743

File Group : 17

Engine Family : K-38 / K-50 750-1500 KVA Node

Service Parts Topic

Background :

The PCC 2100 controller will be introduced on K-38 / K-50 genset applications on 750-1500 KVA nodes for SingleSet from Apr ’07. PCC 3100 is currently used on the above nodes as an optional Genset Paralleling Control. FromApr’07 CIL will be shipping PCC 2100 controller on all 750 – 1500 KVA Gensets which are sold as Stand alonesets. To enable the control to accept Speed & Voltage bias ( 0 – 5Vdc) an add on Module (KIT SYSTEM I/O – PartNo 0541-1291) has to be used. This arrangement will enable the PCC 2100 gensets to be able to parallel withother Gensets. Additional discrete Input and Outputs can be added using the CONTROL KIT(DIM EXP) partnumber 0541-0772

Product Information

AUX 101 PCC 2100 (0300-5459-02)

( KIT SYSTEM I/O 0541-1291)

Addition of AUX 101 will enable the PCC 2100 control to accept Speed Bias & Voltage bias.

Note: Aux 101 is not a standard scope of supply. It needs to be procured separately only if the PCC 2100Genset needs to be paralleled to other genset. One Aux 101 module is needed per PCC 2100 genset.

Connect the Aux 101 module as per instruction sheet (C698) and change the necessary settings as listedbelow.

• Aux 101 – Enable• Speed Bias – Enable• Voltage Bias – Enable• Set the Speed Bias Scale value.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 2 of 17

It is must to adjust the V/Hz table of the PCC2100 to more closely match the V/Hz characteristics of the NewageAVR if you are paralleling with non-PCC Genset. Modify the V/Hz table as shown below on the PCC2100.

Original V/Hz Table Modified V/Hz Table

Hz % Hz %

0.000 100.000 0.000 100.000

3.000 100.000 1.000 100.000

7.313 80.005 5.313 80.005

11.638 50.000 9.638 50.000

15.950 19.995 13.950 19.995

80.00 0.000 80.00 0.000

1) Calibrate Voltage and Current and PF2) Once calibrated, parallel the two Gensets without load and monitor KVARs. If one genset is pushing KVARsonto the other, the Voltage Adjust % command should be used to remove this offset. This parameter is on thefront panel of the PCC2100 and in InPower. Once they are calibrated, they will share load normally.

Part Availability

All the parts are available for service on Onan part number which is printed on the part itself.

Part Information

CONTROL KIT ( SYSTEM I/O) 0541-1291CONTROL KIT(DIM EXP) 0541-772

Field Conversion

Retrofitting on the field is possible only with Stamford alternators.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 3 of 17

Installation and Setup Instructions for I/O Module Kit 541-1320

This instruction sheet describes the installation andconfiguration of an I/O Module on gensets with aPCC2100 control. This Instruction Sheet provides in-formation on how to install the I/O Module kit and pro-vides control configuration information for gensets thatalready have the I/O Module installed.

INTRODUCTION

The PowerCommand I/O Module is an option that canbe used on generator sets with a PCC2100 control.The I/O Module can be used in a 12 or 24 VDC sys-tem.

The PCC2100 control, starting with software version2.500, supports up to two Base I/O Modules and twoExpansion I/O Modules.

If your installation includes both the Base I/O Module(AUX101) and the optional Expansion I/O Module(AUX102), sixteen relay outputs and two discrete ana-log inputs are available for auxiliary control and moni-toring of the power system.

Relay outputs can be used for controlling equipmentsuch as motors, louvers, fans, and pumps. The relayscan be configured individually by using In Power soft-ware.

Base I/O Module (AUX101)

The PowerCommand® AUX101 I/O Module (see Fig-ure 1) includes the following.

• Eight discrete Form-C relay output sets used tocontrol system equipment. Each relay includesa status LED (DS3 thru DS10).

• Inputs 1 and 2 can be configured for voltage andspeed bias as a means to match the voltageand frequency of the generators prior to the con-trol being set up for active droop paralleling op-eration.

• Two 5 VDC voltage sources to be used with ac-tive senders.

• Two network status LEDs.

- DS1 (green) indicates the AUX101 is con-nected to the network and is operating nor-mally.

- DS2 (red) indicates the AUX101 has lost itconnection or is not connected to the network.

• One device number indicator (U16) that is usedto uniquely identify an I/O Module when morethan one AUX101 is included on the same net-work.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 4 of 17

FIGURE 1. BASE I/O MODULE (AUX101)

Since the AUX101 does not require any special con-figuration, it can be used immediately. It includes thefollowing default settings:

• All inputs are disabled except for the two analoginputs

• Outputs are mapped as follows:

1 - Low Oil Pressure2 - High Engine Temperature3- Not Defined4 - Battery (Low, Weak, or High)5 - Overspeed6- Fail to Start7- Not In Auto8- Run

The I/O Module includes the connectors listed inTable 1.

TABLE 1. AUX101 CONNECTORS

Connector Pins Description

J1 5 Connection to 1301 control

J2 12 Dry contact outputs 1 - 4

J3 6 Dry contact outputs 5-6

J4 6 Dry contact outputs 7-8

J5 20 AUX102 connection

J6 6 Not used

J7 6 Not used

J10 12 GND, 5V sources, currentsources

J11 16 Analog/Digital inputs 1 - 8

J14 2 Connection to power source

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 5 of 17

EXPANSION I/O MODULE (AUX102)

The PowerCommand® AUX102 is an Expansion I/OModule (see Figure 2). If your installation is to includean AUX102, your must purchase kit 541-0772.

The AUX102 Expansion I/O Module includes the fol-lowing.

• Eight Form-C relay output sets used to control sys-tem equipment. Each relay includes a status LED (DS1thru DS8).

A ribbon cable is used to connect the Expansion I/OModule to the Base I/O Module. The AUX102 includesthe following default settings:

• All inputs are disabled

• Outputs are mapped as follows:

9 - Pre-Low Oil Pressure

10 - Pre-High Engine Temperature

11 - Not Defined

12 - Not Defined

13 - Low Engine Temperature

14 - Not Defined

15 - Not Defined

16 - Not Defined

FIGURE 2. EXPANSION I/O MODULE (AUX102)

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 6 of 17

INSTALLATION

The following parts are included in the I/O Modulekit.

Description Qty.

I/O Module 1

Connector (2 Pin) 1

Connector (5 Pin) 1

The following part is not included in the I/O Module kitbut may be needed for your installation.

Description Part Number

Expansion I/O Module 541-0772

Read these instructions completely and becomefamiliar with safety warnings, cautions, and proceduresbefore starting the installation.

Mounting Guidelines

The I/O Module is suitable for non-engine panelmounting within an enclosure. As such, it should notbe directly mounted on the engine.

To prevent the I/O Module from being exposed toconditions beyond its specifications, care should betaken not to mount it close to the engine exhaust pipes.Avoid mounting the Module(s) in a manner that wouldexpose them to direct sunlight or rain/ snow.

Choose a clean, vibration-free mounting surface. Avoidlocations that are hot, damp, or dusty or that are closeto EMI sources. The AUX101 and AUX102 aredesigned for proper operation in ambient temperaturesfrom -40 to +60 Degrees C (-40 to 140 Degrees F),and for storage from -40 to +80 Degrees C (-40 to 176Degrees F). The modules are designed to operate withhumidity up to 95%, non-condensing.

Physical Installation

WARNING Incorrect installation, service, orreplacement of parts can result in severe personalinjury or death and/or equipment damage. Only trainedand experienced personnel are to perform the followingprocedures.

!

WARNING AC voltages and currents present anelectrical shock hazard that can cause severe personalinjury or death. Incorrect installation, service, or partsreplacement can result in severe personal injury, death,and/or equipment damage.

CAUTION If present, always disconnect a batterycharger from its AC source before disconnecting thebattery cables. Otherwise, disconnecting the cablescan result in voltage spikes high enough to damagethe DC control circuits of the generator set.

WARNING Accidental starting of the generator setwhile working on it can cause severe personal injuryor death. Prevent accidental starting by disconnectingthe starting battery cables (negative [-] first).

Make certain the battery area has been well-ventilatedbefore servicing the battery—Wear goggles—Stop thegenset and disconnect the charger beforedisconnecting battery cables. Arcing can igniteexplosive hydrogen gas given off by batteries, causingsevere personal injury. Arcing can occur when a cableis removed or re-attached, or when the negative (-)battery cable is connected and a tool used to connector disconnect the positive (+) battery cable touchesthe frame or other grounded metal part of the generatorset. Always remove the negative (-) cable first, andreconnect it last. Make certain hydrogen from thebattery, engine fuel, and other explosive fumes arefully dissipated. This is especially important if thebattery has been connected to a battery charger.

WARNING Ignition of explosive battery gases cancause severe personal injury or death. Arcing at batteryterminals, light switch or other equipment, flame, pilotlights and sparks can ignite battery gas. Do not smoke,or switch trouble light ON or OFF near a battery.Discharge static electricity from body before touchingbatteries by first touching a grounded metal surface.

Refer to the PCC2100 Control wiring diagram(Figure 12) when connecting the I/O Module to thePCC2100 control. This wiring diagram also includesinformation on wiring items (annunciator and governorpower module) not included in this kit.

!

!

!

!

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 7 of 17

Refer to the I/O Module wiring diagram (Figure 11)when connecting the I/O Module to other equipment.

NOTE: Mounting hardware for the I/O Module is notincluded in this kit. The instructions below includesuggested hardware sizes.

1. Make sure the generator set is shut down anddisabled:

a. The PCC2100 is in the Off mode.

b. The generator set Run/Off/Auto switch is inthe Off position and the generator is cool (tothe touch).

c. The battery charger (if equipped) is turnedoff and disconnected.

d. The negative (-) cable from the battery isdisconnected to prevent accidental starting.

2. Select a suitable location and mount the I/OModule using M4 hardware. Figure 3 shows theModule dimensions (including the Expansion I/O

Module). The outside dimensions do not includenecessary clearance for wire connections.

3. If included in your installation, use M4 hardwareto mount the Expansion I/O Module (kit 541-0772)near the Base I/O Module and plug the ExpansionI/O Module’s J6 connector into the Base I/OModule’s J5 connector. Be sure to use a screwand lock washer to ground the J5 ring terminal.

4. Select appropriate wire and connect wiring fromthe PCC2100 baseboard TB1 connector to theenclosed 5-pin connector (see Figure 12). Plugthe connector into the J1 connector ontheAUX101.

5. Connect any system equipment to the dry contactoutput connectors on the AUX101 (J2, J3, andJ4) and, if installed, the AUX102 (J1, J2, and J3).

6. Make connections for any analog/discrete inputsto the J11 connector on the AUX101 and, ifinstalled, the J4 connector on the AUX102.

7. If needed, connect GND, 5V sources, and currentsources to the J10 connector on the AUX101.

FIGURE 3. I/O MODULE FOOTPRINT

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 8 of 17

8. Select appropriate wire for power connections andinstall wiring on the enclosed 2-pin connector.Connect the wiring to the power source (PCC2100TB2-3 = B+ and TB2-4 = B-/GND - see Figure 4)and plug the connector into the J14 connector onthe AUX101.

9. Reconnect the genset as follows.

a. Connect the negative (-) cable to the battery.

b. Reconnect the battery charger (if used).

c. Place the Run/Off/Auto switch to the desiredposition.

d. Set the PCC2100 to the desired mode.

FIGURE 4. PCC2100 CONTROL WIRING CONNECTIONS

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 9 of 17

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

10. Verify that the DS1 LED on the AUX101 is greenand that all devices are powered.

11. If your installation includes only one AUX101, thedevice number displayed on the module is “0”(see Figure 1). If your installation includes morethan one AUX101,

a. Press and hold the S1 (DEV#) button for aleast five seconds, until a small dot appearsnext to the number displayed on the devicenumber indicator.

b. To change the device number, press andrelease S1 until the desired number isdisplayed. After five seconds of inactivity, thenew device number is set and the small dotwill go out.

c. After the device number has been changed,cycle power from the I/O Module byunplugging and replugging the J14 connector.

NOTE: The PCC2100 genset control currentlysupports up to two AUX101s. If you are usingthe speed/voltage bias inputs on an AUX101,the device number on that AUX101 must beset to “0.”

12. Configure the I/O Module(s), as described in thefollowing pages.

I/O MODULE CONFIGURATION

The I/O Module can only be configured using the PCservice tool.

The AUX101 is a plug and play device. Onceconnected to the PCCNet network, the PCC2100should recognize it there. Up to two AUX101 s can beconnected to a PCC2100. The user can disable anAUX101 by changing the AUX101(s) Enable setting to“Disable” (see Figure 5).

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 10 of 17

FIGURE 6. VOLTAGE AND SPEED BIAS ENABLE

Although the AUX101 is designed for twelve networkinputs, only two of the inputs can currently be usedwith the PCC2100 control. If more than one AUX101is connected to a PCC2100, speed and voltage biaswill only function on the device with the device num-ber set to 0.

Input 1 of the AUX101 is set up as a Voltage Bias

input. It can only be used as a voltage bias input. Thisfeature must be enabled by changing the Voltage BiasEnable value to “Enable.”

Input 2 of the AUX101 is set up as a Speed Biasinput. It can only be used as a speed bias input. Thisfeature must be enabled by changing the Speed BiasEnable value to “Enable.”

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 11 of 17

FIGURE 7. SPEED BIAS SCALE

The Voltage Bias input has a range of -3V to +3V, with0V input corresponding to 0 voltage bias. The SpeedBias has a range of 0V to 5V with 2.5V input corre-sponding to 0 speed bias.

Both inputs have a “Scale” parameter which sets upthe minimum and maximum voltage or RPM

values that correspond to the AUX101 input voltages.For example, if the Speed Bias scale is set to 200RPMs, a 5V input into the AUX101 changes the speedreference +200 RPMs. A 0V input into the AUX101changes the speed reference -200 RPMs. The VoltageBias Scale acts the same way.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 12 of 17

FIGURE 8. OUTPUT FAULT MENU FOR AUX101 DEVICE #1

All of the available relay outputs are supported withthe PCC2100. Outputs 1-8 are available with theAUX101 and outputs 9-16 are available if the

AUX102 expansion board is installed. Although eachoutput has a default fault assigned to it, they can bechanged using the menu shown below.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 13 of 17

Figure 9 shows the menu that can be used to changethe output values if a second AUX101 and AUX102are installed.

FIGURE 9. OUTPUT FAULT MENU FOR AUX101 DEVICE #2

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 14 of 17

FIGURE 10. AUX101 MONITORING SCREEN

The monitoring screen shown in Figure 10 displaysinformation about the AUX101 devices connected tothe PCC2100. It shows if an expansion board is

installed and it shows the voltage and speed biasvalues based on the “Scale” value.

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 15 of 17

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 16 of 17

Cummins India LimitedRegistered Office : Kothrud, Pune 411 038 (India)

SPT 3242743 Page 17 of 17

Note: This is product improvement and not subject to campaign