Professional Documents
Culture Documents
Control 1302
Operator Instructions
8-2006
i
Table of Contents
SECTION TITLE PAGE
1 PCC 1302 Control Operation 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC 1302 Features 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Status Output 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Mode 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Run Mode 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Mode 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleep Mode 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring Sleep In Auto Mode 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with a Control Panel 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with a Manual Run/Off/Auto Switch 1-3 . . . . . . . . . . . . . . . . . . . . . .
Battle Short Mode 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with a Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations without a Control Panel 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphical Display 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Text / Symbolic Versions 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Menu Selection Buttons 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Previous Main Menu Button 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Button 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not In Auto Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Run Indicator 1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel System Messages 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Messages 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Messages 1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Messages 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Reset / Acknowledgement 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault/Status Codes 1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Default Settings 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saving Your Changes 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Menus 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Status Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Status Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Line-to-Line Voltage Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Line-to-Neutral Voltage Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Single Phase Voltage Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Amperage Menu 1-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Table of Contents (Continued)
SECTION TITLE PAGE
Selecting Auto, Manual Run, and Off Modes 1-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entering the Mode Change Access Code 1-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Auto Mode 1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Manual Run Mode 1-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aborting the Transition to Auto or Manual Run Mode 1-19 . . . . . . . . . . . . . . . . . . . .
Selecting Off Mode 1-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Menus 1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Menu 1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Status Menus 1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History / About Menus 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History Submenu 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Genset Submenus 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Control Submenu 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Display Submenu 1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault History Menu 1-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Adjust Menu 1-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Values/Parameters 1-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Adjust Menu 1-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1. PCC 1302 Control Operation
TB15
TB1
J20
DS1 LED
STATUS
INDICATOR
J12
J17
J18
J22
J11
J25
FIGURE 1-1. PCC 1302 CONTROL BOARD
The following describes the function and operation
of the PowerCommand
G
o
v
P
S
A
B
J17 AVR Control
J18 AVRPower
Switched
B+
LS Out
LS Out
LS Out
Driver
Rating:
4Amps
Peak: 6
Amps
Relay B+ internally
fused at 1.85A
OR
Low Oil Pressure
Switch
J11 3
J11 2
Input
Return
Relay B+ internally
fused at 1.85A
B.C. Alt. Flash
internally fused at
1.5A
Use L1/L2/N
for 1 phase
applications
Don tconnect
N in Delta
configuration
HMI Fused B+and
Customer Fused B+
share a common 4.5A
fuse.
HMI Fused B+ is
assumed to consume
no more than 1.5A
Part numbers
J25 Mate: 03232445
Sockets: 03232466
Part numbers
J11 Mate: 03232161
Sockets: 03232466
Part numbers
J20 Mate: 03232446
Sockets: 03232466
Part numbers
J12 Mate: 03231932
Sockets: 03231200
Part numbers
J22 Mate: 0323222603
Part numbers
J17 Mate: 03232098
Sockets: 03231200
Part numbers
J18 Mate: 03232444
Sockets: 03231200
Part numbers
PCC 1302: 0327161701
Part numbers
Aux 104: 03271507
J1 Mate: 03232216: Sockets: 03231200
Fused B+
These signals
go to the
display but
don tgo
through the
PCC controller.
Terminal
Block
J20
Harness
Remote Estop
PB (B)
Basic
Customer
Fused B+
Fused B+
These signals
go to the
engine but
don t go
through the
PCC controller.
Terminal
Block
J20
Harness
B+ Return J20
Harness
Fused B+
B+ Return
Gov PS Power Fused B+
Fused B+
These signals
go to the
genset but
don t go
through the
PCC controller.
Terminal
Block
J11
Harness
B+ Return
J11, J25
Harness
Basic
Customer
Estop B+ Power
HMI2xx
or HMI3xx
Display
HMI Fuse B+
B+ Return
PCC Net A (+)
PCC Net B ()
Run (Wakeup)
Auto
(Configurable Wakeup)
System Wakeup
J2510
J2511
J254
J253
J255
J2512
J258
Use Shielded Twisted Pair for PCC Net
Only terminate shield on one end
Part numbers
HMI 220:
03006314
HMI 320:
03006315
J28 Mate:
03232091
J29 Mate:
03232456
Sockets: 03232466
J29 6
J29 4
J29 1
J29 2
J29 3
J28 1
J28 2
HMI 112
Bargraph
HMI Fuse B+
B+ Return
PCC Net A (+)
PCC Net B ()
System Wakeup
J254
J253
J255
J2512
J258
Part numbers
HMI 112:
0300605002
J1 & J6 Mate:
03232011
Sockets: 03232466
J1 3
J1 4
J1 5
J6 1
J6 2
Locate near
mounting screw
chassis.
HMI211
Display
HMI Fuse B+
B+ Return
PCCNet A (+)
PCCNet B()
Manual (Wakeup)
Auto (Configurable Wakeup)
J1 6
J1 7
System Wakeup
J1 1
J1 2
J1 4
J1 3
J1 5
J2510
J2511
J254
J253
J255
J2512
J258
Part numbers
HMI211:
03006014
OR
Local
FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEET 2 OF 4)
1-29
No. 630-3270 Sh 1 of 4
Rev. Sys: ProE
Modified 7/2006
PCC1302
Baseboard
Battery
Charger
Aux 101
Remote I/O
Customer Fused B+
B+ Return
Customer Fused B+
B+ Return
PCC Net A (+)
PCCNet B ()
System Wakeup
PCCNet A (+)
PCCNet B()
System Wakeup
PCC1302 Customer Connections:
PCC Net Devices
TB1 1
TB1 2
TB15 5
TB1 5
TB1 3
TB1 1
TB1 2
TB15 5
TB1 5
TB1 3
TB 1
HMI2xx
and
HMI3xx
Display
Customer Fused B+
B+ Return
PCC Net A (+)
PCCNet B ()
System Wakeup
TB1 1
TB1 2
TB15 5
TB1 5
TB1 3
Use Shielded Twisted Pair for PCC Net
Only terminateshield on one end, to
prevent groundloops
J1 3
J1 4
J1 5
J14 1
J14 2
Discrete Input (Sense)
Return
Aux 101
Relay 1
Output
J2 1
J2 3
Relay NO
J2 2 Relay Com
RelayNC
Aux 101
Relay 2
Output
J2 4
J2 6
Relay NO
J2 5 Relay Com
RelayNC
Aux 101
Relay 3
Output
J2 7
J2 9
Relay NO
J2 8 Relay Com
RelayNC
Aux 101
Relay 4
Output
J2 10
J2 12
Relay NO
J2 11 Relay Com
RelayNC
Aux 101
Relay 5
Output
J3 1
J3 3
Relay NO
J3 2 Relay Com
RelayNC
Aux 101
Relay 6
Output
J3 4
J3 6
Relay NO
J3 5 Relay Com
RelayNC
Aux 101
Relay 7
Output
J4 1
J4 3
Relay NO
J4 2 Relay Com
RelayNC
Aux 101
Relay 8
Output
J4 4
J4 6
Relay NO
J4 5 Relay Com
RelayNC
J11 1
J11 2
AND/
OR
J11 3
J11 4
Input #1 Input #2
+/5V Analog
Input
Sense
Return Oil
Temperature
RTD
Sensor
J11 5 Sense
J10 3 Current source
AND
/OR
J11 7
J10 4
Input #3 Input #4
J11 9
J10 5
Input #5
J11 11
J10 6
Input #6
J10 9 Current return
J11 6 Sense return
J10 10
J11 8
J10 11
J11 10
J10 12
J11 12
Exhaust Stack
Temperature #1
RTD
Sensor
Sense
Current source
Current return
Sense return
Ambient
Temperature
RTD
Sensor
Sense
Current source
Current return
Sense return
Fuel Level
Sensor
RTD
Sensor
Sense
Current source
Current return
Sense return
Intake Manifold
Temperature
RTD
Sensor
Sense
Current source
Current return
Sense return
05VAnalog Input
Sense
Sense return
038V Analog
Input
J11 13 Sense
J11 14 Return
AND
/OR
J11 15
J11 16
Input #7 Input #8
Gnd must be
wired in
Customer
Fused B+
Discrete Input (Sense)
Return
Gnd must be
wired in
OR
OR
OR
OR
OR
OR
OR
Discrete Input (Sense)
Return
Gnd must be
wired in
Customer
Fused B+
Discrete Input (Sense)
Return
Gnd must be
wired in
OR
OR
Discrete Input (Sense)
Return
Gnd must be
wired in
Customer
Fused B+
Discrete Input (Sense)
Return
Gnd must be
wired in
OR
OR
Aux 102
Remote I/O
J5
J6
J1
Aux 102
Relay 9
Output
J1 1
J3 1
Relay NO
J2 1 Relay Com
RelayNC
Aux 102
Relay 10
Output
J1 2
J3 2
Relay NO
J2 2 Relay Com
RelayNC
Aux 102
Relay 11
Output
J1 3
J3 3
Relay NO
J2 3 Relay Com
RelayNC
Aux 102
Relay 12
Output
J1 4
J3 4
Relay NO
J2 4 Relay Com
RelayNC
Aux 102
Relay 13
Output
J1 5
J3 5
Relay NO
J2 5 Relay Com
RelayNC
Aux 102
Relay 14
Output
J1 6
J3 6
Relay NO
J2 6 Relay Com
RelayNC
Aux 102
Relay 15
Output
J1 7
J3 7
Relay NO
J2 7 Relay Com
RelayNC
Aux 102
Relay 16
Output
J1 8
J3 8
Relay NO
J2 8 Relay Com
RelayNC
J2
J3
Chassis Ground
Mounting screw
Maximum
of 2 Aux
101 &
102s can
be used
per
genset
J11
J10
J4
J3
J2
TB 15
Use a local, floating (nongrounded)
DCpower supply if B+ line has high
resistance (>1 ohm) due to long runs,
to prevent brief poweroutages during
genset starts
PCC Net must use a daisy chain
topology only
HMI 113
Annunciator
Customer Fused B+
B+ Return
PCC Net A (+)
PCCNet B ()
TB1 1
TB1 2
TB1 5
TB1 3
HMI 112
Bargraph
Customer Fused B+
B+ Return
PCC Net A (+)
PCCNet B ()
System Wakeup
TB1 1
TB1 2
TB15 5
TB1 5
TB1 3
J23
J24
TB116
TB115
J15
J13
J14
J61
J62
J
4
J4 1
J4 2
Input
Return Input #9
J4 3
J4 4 Return Input #10
Input
J4 5
J4 6 Return Input #11
Input
J4 7
J4 8 Return Input #12
Input
J10 7
J10 9
5VDCSupply #1
(20 mA max)
+
Return
J10 8
J10 10
5VDC Supply #2
(20 mA max)
+
Return
J10
Part numbers
Aux 101:
03271536
Part numbers
Aux 102:
03271265
Part numbers
w/o enclosure:
300592901
w/ enclosure:
300592902
Part numbers
HMI 112: 0300605002
Aux 102
Relay Output
Ratings:
2A,
30VDC,
250VAC
Aux 101
Relay Output
Ratings:
30VDC,
250VAC
NO: 5A
NC: 3A
AND
/OR
AND
/OR
Part numbers
Aux 101 mates:
J1: 0323219204
J14: 0323167802
Others: comew/ board
Aux 102 mates:
J1, J2, J3: 0323167808
J4: 0323167807
Others: comew/ board
Refer to the PCCNetSpec Sheet for
further detailson PCCNet
HMI211
Customer Fused B+
B+ Return
PCC Net A (+)
PCC Net B ()
System Wakeup
TB1 1
TB1 2
TB15 5
TB1 5
TB1 3
Remote Start TB110
J1 7
J1 4
J1 1
J1 2
J1 3
J1 5
Remote
Part numbers
HMI211:
03006014
J29 3
J29 1
J29 2
J28 1
J28 2
FIGURE 1-20. PCC 1302 WIRING DIAGRAM
(SHEEET 3 OF 4)
1-30
No. 630-3270 Sh 1 of 4
Rev. Sys: ProE
Modified 7/2006
PCC 1302 Baseboard
PCC1302 Customer Connections:
Relay Output
Ratings:
3.5 A,
30VDC,
250VAC
Customer
Output #1
TB1 6 Relay NO
TB1 7 Relay Com
See Application Notes
section for high level
Estopcircuit
TB1 Basic
TB1 11
TB1 10
Input
Return
Remote
Start
(Wakeup)
TB1 12
TB1 13 Return
Customer
Input #1
Input
TB1 14
TB1 15 Return
Customer
Input #2
Input
TB1 5
TB1 10
Customer fused
Battery Supply
(3A max)
+
Return
Customer
Output #2
TB1 8 Relay NO
TB1 9 Relay Com
Battery
+
Remote
Estop
PB
(Remove jumper
if not used)
Input (Wakeupon open)
Return
TB1 16
TB1 15
EstopB+ Power
A
B
Local Estop PB (B)
PCC Net
Devices
(See Customer
PCC Net page)
PCC Net A (+) RS485
PCC Net B () RS485
TB1 1
TB1 2
PCC Net B Shield TB1 3
TB1 4
Ready To
Load Output
LowSide Driver
Items in dashed lines
represent internal
PCC circuitry.
System Wakeup TB15 5
TB15 Modbus/PC Tool
Modbus
System Wakeup:
Ground if the PCC
control system is to
always stay awake.
(+)
()
RS485 (+)
RS485 ()
Shield
120
Ohm
120 ohm terminated
Only terminate shield
on one end
TB15 3
TB15 4
TB15 1
PCC Net
Devices
(See Customer
PCC Net page)
PC Tool Harness
PC Tool
OR
Part numbers
TB 15 Mate: 0323219204
Part numbers
TB 8 Mate: 0323232503
Part numbers
TB 1 Mate: 03232434
Part numbers
PC Tool Harness kit: 05411199
EstopB+ Power
These signals
go to the
customer but
don t go
through the
PCC controller.
Terminal
Block
J20
Harness
Local Estop PB
(B)
J25
Harness
FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEET 4 OF 4)