CUMMIN AUX101

Service Parts Topic

Date

:

December, 2006

No.

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3242743

File Group

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17

Engine Family : Subject

:

Ref. No.

:

FESN

:

Application Group :

K-38 / K-50 750-1500 KVA Node

Introduction of AUX 101 (add on Module to PCC 2100 Genset Controls) to enable the Control for Parallel application.

G-drive

Background : The PCC 2100 controller will be introduced on K-38 / K-50 genset applications on 750-1500 KVA nodes for Single Set from Apr ’07. PCC 3100 is currently used on the above nodes as an optional Genset Paralleling Control. From Apr’07 CIL will be shipping PCC 2100 controller on all 750 – 1500 KVA Gensets which are sold as Stand alone sets. To enable the control to accept Speed & Voltage bias ( 0 – 5Vdc) an add on Module (KIT SYSTEM I/O – Part No 0541-1291) has to be used. This arrangement will enable the PCC 2100 gensets to be able to parallel with other Gensets. Additional discrete Input and Outputs can be added using the CONTROL KIT(DIM EXP) part number 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 2100 Genset 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 listed below. • • • •

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

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It is must to adjust the V/Hz table of the PCC2100 to more closely match the V/Hz characteristics of the Newage AVR if you are paralleling with non-PCC Genset. Modify the V/Hz table as shown below on the PCC2100. Original V/Hz Table Hz % 0.000 100.000 3.000 100.000 7.313 80.005 11.638 50.000 15.950 19.995 80.00 0.000

Modified V/Hz Table Hz % 0.000 100.000 1.000 100.000 5.313 80.005 9.638 50.000 13.950 19.995 80.00 0.000

1) Calibrate Voltage and Current and PF 2) Once calibrated, parallel the two Gensets without load and monitor KVARs. If one genset is pushing KVARs onto the other, the Voltage Adjust % command should be used to remove this offset. This parameter is on the front 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) CONTROL KIT(DIM EXP)

0541-1291 0541-772

Field Conversion Retrofitting on the field is possible only with Stamford alternators.

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Installation and Setup Instructions for I/O Module Kit 541-1320 This instruction sheet describes the installation and configuration of an I/O Module on gensets with a PCC2100 control. This Instruction Sheet provides information on how to install the I/O Module kit and provides control configuration information for gensets that already have the I/O Module installed. INTRODUCTION The PowerCommand I/O Module is an option that can be used on generator sets with a PCC2100 control. The I/O Module can be used in a 12 or 24 VDC system. The PCC2100 control, starting with software version 2.500, supports up to two Base I/O Modules and two Expansion I/O Modules.

Base I/O Module (AUX101) The PowerCommand® AUX101 I/O Module (see Figure 1) includes the following. • Eight discrete Form-C relay output sets used to control system equipment. Each relay includes a status LED (DS3 thru DS10). • Inputs 1 and 2 can be configured for voltage and speed bias as a means to match the voltage and frequency of the generators prior to the control being set up for active droop paralleling operation. • Two 5 VDC voltage sources to be used with active senders.

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 analog inputs are available for auxiliary control and monitoring of the power system.

• Two network status LEDs. - DS1 (green) indicates the AUX101 is connected to the network and is operating normally. - DS2 (red) indicates the AUX101 has lost it connection or is not connected to the network.

Relay outputs can be used for controlling equipment such as motors, louvers, fans, and pumps. The relays can be configured individually by using In Power software.

• One device number indicator (U16) that is used to uniquely identify an I/O Module when more than one AUX101 is included on the same network.

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Since the AUX101 does not require any special configuration, it can be used immediately. It includes the following default settings:

TABLE 1. AUX101 CONNECTORS Connector

Pins

• All inputs are disabled except for the two analog inputs

J1

5

Connection to 1301 control

J2

12

Dry contact outputs 1 - 4

• Outputs are mapped as follows:

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, current sources

J11

16

Analog/Digital inputs 1 - 8

J14

2

Connection to power source

12345678-

Low Oil Pressure High Engine Temperature Not Defined Battery (Low, Weak, or High) Overspeed Fail to Start Not In Auto Run

The I/O Module includes the connectors listed in Table 1.

Description

FIGURE 1. BASE I/O MODULE (AUX101)

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EXPANSION I/O MODULE (AUX102)

• All inputs are disabled

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

• Outputs are mapped as follows:

The AUX102 Expansion I/O Module includes the following. • Eight Form-C relay output sets used to control system equipment. Each relay includes a status LED (DS1 thru DS8). 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:

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)

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INSTALLATION The following parts are included in the I/O Module kit. Description I/O Module Connector (2 Pin) Connector (5 Pin)

Qty. 1 1 1

The following part is not included in the I/O Module kit but may be needed for your installation. Description Expansion I/O Module

Part Number 541-0772

Read these instructions completely and become familiar with safety warnings, cautions, and procedures before starting the installation. Mounting Guidelines The I/O Module is suitable for non-engine panel mounting within an enclosure. As such, it should not be directly mounted on the engine. To prevent the I/O Module from being exposed to conditions beyond its specifications, care should be taken not to mount it close to the engine exhaust pipes. Avoid mounting the Module(s) in a manner that would expose them to direct sunlight or rain/ snow. Choose a clean, vibration-free mounting surface. Avoid locations that are hot, damp, or dusty or that are close to EMI sources. The AUX101 and AUX102 are designed for proper operation in ambient temperatures from -40 to +60 Degrees C (-40 to 140 Degrees F), and for storage from -40 to +80 Degrees C (-40 to 176 Degrees F). The modules are designed to operate with humidity up to 95%, non-condensing. Physical Installation ! WARNING Incorrect installation, service, or replacement of parts can result in severe personal injury or death and/or equipment damage. Only trained and experienced personnel are to perform the following procedures.

! WARNING AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Incorrect installation, service, or parts replacement can result in severe personal injury, death, and/or equipment damage.

CAUTION 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 Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative [-] first). !

Make certain the battery area has been well-ventilated before servicing the battery—Wear goggles—Stop the genset and disconnect the charger before disconnecting battery cables. Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when a cable is removed or re-attached, or when the negative (-) battery cable 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, light switch or other equipment, flame, pilot lights 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 touching batteries by first touching a grounded metal surface. !

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

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

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 not included in this kit. The instructions below include suggested hardware sizes. 1.

2.

3.

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

4.

Select appropriate wire and connect wiring from the PCC2100 baseboard TB1 connector to the enclosed 5-pin connector (see Figure 12). Plug the connector into the J1 connector ontheAUX101.

5.

Connect any system equipment to the dry contact output connectors on the AUX101 (J2, J3, and J4) and, if installed, the AUX102 (J1, J2, and J3).

Make sure the generator set is shut down and disabled: a.

The PCC2100 is in the Off mode.

b.

The generator set Run/Off/Auto switch is in the Off position and the generator is cool (to the touch).

c.

The battery charger (if equipped) is turned off and disconnected.

d.

The negative (-) cable from the battery is disconnected to prevent accidental starting.

6.

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

Make connections for any analog/discrete inputs to the J11 connector on the AUX101 and, if installed, the J4 connector on the AUX102.

7.

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

FIGURE 3. I/O MODULE FOOTPRINT

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8.

9.

Select appropriate wire for power connections and install wiring on the enclosed 2-pin connector. Connect the wiring to the power source (PCC2100 TB2-3 = B+ and TB2-4 = B-/GND - see Figure 4) and plug the connector into the J14 connector on the AUX101.

a.

Connect the negative (-) cable to the battery.

b.

Reconnect the battery charger (if used).

c.

Place the Run/Off/Auto switch to the desired position.

d.

Set the PCC2100 to the desired mode.

Reconnect the genset as follows.

FIGURE 4. PCC2100 CONTROL WIRING CONNECTIONS

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10. Verify that the DS1 LED on the AUX101 is green and that all devices are powered. 11. If your installation includes only one AUX101, the device number displayed on the module is “0” (see Figure 1). If your installation includes more than one AUX101, a. Press and hold the S1 (DEV#) button for a least five seconds, until a small dot appears next to the number displayed on the device number indicator. b. To change the device number, press and release S1 until the desired number is displayed. After five seconds of inactivity, the new device number is set and the small dot will go out. c. After the device number has been changed, cycle power from the I/O Module by unplugging and replugging the J14 connector.

NOTE: The PCC2100 genset control currently supports up to two AUX101s. If you are using the speed/voltage bias inputs on an AUX101, the device number on that AUX101 must be set to “0.” 12. Configure the I/O Module(s), as described in the following pages. I/O MODULE CONFIGURATION The I/O Module can only be configured using the PC service tool. The AUX101 is a plug and play device. Once connected to the PCCNet network, the PCC2100 should recognize it there. Up to two AUX101 s can be connected to a PCC2100. The user can disable an AUX101 by changing the AUX101(s) Enable setting to “Disable” (see Figure 5).

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

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Although the AUX101 is designed for twelve network inputs, only two of the inputs can currently be used with the PCC2100 control. If more than one AUX101 is connected to a PCC2100, speed and voltage bias will only function on the device with the device number 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. This feature must be enabled by changing the Voltage Bias Enable value to “Enable.” Input 2 of the AUX101 is set up as a Speed Bias input. It can only be used as a speed bias input. This feature must be enabled by changing the Speed Bias Enable value to “Enable.”

FIGURE 6. VOLTAGE AND SPEED BIAS ENABLE

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The Voltage Bias input has a range of -3V to +3V, with 0V input corresponding to 0 voltage bias. The Speed Bias has a range of 0V to 5V with 2.5V input corresponding to 0 speed bias. Both inputs have a “Scale” parameter which sets up the minimum and maximum voltage or RPM

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

FIGURE 7. SPEED BIAS SCALE

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All of the available relay outputs are supported with the PCC2100. Outputs 1-8 are available with the AUX101 and outputs 9-16 are available if the

AUX102 expansion board is installed. Although each output has a default fault assigned to it, they can be changed using the menu shown below.

FIGURE 8. OUTPUT FAULT MENU FOR AUX101 DEVICE #1

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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

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

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

FIGURE 10. AUX101 MONITORING SCREEN

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Note: This is product improvement and not subject to campaign

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