pcc1302 operator instructions

5/23/2018 PCC1302 Operator Instructions

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PowerCommandControl 1302Operator Instructions


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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


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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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1. PCC 1302 Control Operation

TB15

TB1

J20

DS1 LEDSTATUS

INDICATOR

J12

J17

J18

J22

J25


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A PCC 1302 installation may also include the fol-lowing options.

If a control panel is mounted on the genset(local display), one additional control panelcan be mounted up to 4000 feet from thegenset (remote displays). A setup menu inthe optional display panel is required to des-ignate a display as Local or Remote.

Local status indicator lamp driver

Remote and local emergency stop

Four configurable inputs

Annunciator fault inputs 1, 2, and 3 Theseoutputs can be used when an annunciator isinstalled as part of an PCCNet interface con-nected to TB1-2 and TB1-3. Grounding oneof these inputs on the annunciator activatesthe corresponding warning or shutdown se-quence.

Three Customer Annunciator Text messagesubmenus are supplied to enter the event typeand description (see page 1-28).

ECM CAN engine interface

Local Status Output

is flashed, followed by a half-second pauseand the third digit is flashed, followed by a half-second pause and then the fourth digit isflashed, followed by a two-second pause.

NOTE: Only the last shutdown fault is flashed.

OPERATING MODES

The PCC 1302 works with a Manual Run/Off/Autoswitch, used to control genset operating modes.This capability is located either in the harness(switch) or is integrated into the optional control pan-

el.

Off Mode

When in Off mode, the control does not allow thegenset to start. If the genset is already running andthe control is set to Off, it initiates a normal shut-down sequence.

Manual Run Mode

When in Manual Run mode, the genset starts andcontinues to run until the control is put into the Offmode. While in Manual Run mode, the remote startsignal is ignored.


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Emergency Stop Mode

When an optional emergency stop button is used, itimmediately shuts down the generator set, bypass-

ing any time delay stop. If an optional emergencystop is not used, the local and remote E-stop sig-nals must be shorted to GND. The red ShutdownLED lights and one of the two emergency stop faultcodes (1433 Local Emergency Stopor 1434 Remote Emergency Stop) is either displayed(installations with a control panel) or flashed (instal-lations with a status indicator lamp), depending onwhich was activated last.

To reset the control, close (disable) the activeemergency stop button(s) and perform a fault reset(see page 1-9).

Sleep Mode

The PCC 1302 control enters a low power (sleep)mode of operation where the current draw is not

greater than 60 milliamps (DC) at normal batteryvoltage levels. The control is set to enter sleepmode after five minutes in Off mode or Auto mode,if configured. (Sleep mode can be disabled if a

jumper is installed connecting TB15-1 to TB15-5.)

The control will not enter the sleep mode if there are

5. Disconnect the PCC 1302 from InPower.

Installations with a Control Panel

Sleep mode is automatically enabled on the controlpanel. The PCC 1302 control determines that itshould sleep when the display panel has had nokey presses for five minutes and wake-up signalsare inactive. The control system can be awakenedby pressing the keypad on the control panel or byactivating any wake-up input.

Installations with a Manual Run/Off/Auto

Switch

For installations that utilize an Manual Run/Off/Autoswitch located in the harness, the control awakesfrom sleep mode if Manual Run mode is selected.The control will also wake up if Auto mode is se-lected and the control is configured to stay awakewhen in Auto mode, Wake-In-Auto = Enabled.

Battle Short Mode

The purpose of Battle Short is to satisfy local coderequirements, where necessary. To use this fea-ture, the necessary software must either beinstalled at the factory when the PCC 1302 is pur-chased or else installed by a customer service rep


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Installations with a Control Panel

Battle Short can be enabled or disabled (set to Ac-tive or Inactive) using the control panel.

The PC service tool is required to enable theBattle Short mode feature. Contact an autho-rized service center for assistance.

Before Battle Short can be used on installationswith the display panel, the Switch Input setting onthe Battle Short submenu must be set to OperatorPanel (see page 1-11). In addition, Battle Shortmode must be enabled (set to Active) in the Battle

Short submenu (see page 1-11).When Battle Short mode is enabled, the Warningstatus indicator lights, and code 1131 Battle ShortActiveis displayed.

When Battle Short mode is enabled and anoverrid-den shutdown fault occurs, the shutdown lamp re-mains lit even though the genset continues to run.Fault code 1416 Fail to Shut Downis displayed. If

the , , or button is pressed to acknowledgethe fault, the fault message is cleared from the dis-play but remains in the Fault History file.

Battle Short is suspended and a shutdown occursimmediately if:

A f th f ll i h td f lt

(see page 1-11) and select Inactive. Faultcode 1123 Shutdown After Battle Shortis then displayed.

Installations without a Control Panel

A Manual Run/Off/Auto switch must be installed ininstallations that do not include a control panel.Battle Short can be turned on or off with a customerinstalled external switch connected to one of thefour configured inputs.

The PC service tool is required to enable theBattle Short mode feature and to enable the ex-

ternal Battle Short switch using one of the fouravailable customer inputs. Contact an autho-rized service center for assistance.

When Battle Short mode is enabled and an overrid-den shutdown fault occurs, the genset continues torun and the status indicator lamp flashes the shut-down fault code. See Local Status Output on page1-2 for information on interpreting the status indi-

cator light.

Battle Short is suspended and a shutdown occursimmediately if:

Any of the following shutdown faults occurs.

Overspeed Fault code 234


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PREVIOUS MENU

LEVEL BUTTON

GRAPHICALDISPLAY

OFF MODEBUTTON

DISPLAY MENU

SELECTION BUTTONS

LEDINDICATORS

HMI1211

FIGURE 1-2. PCC 1302 OPTIONAL CONTROL PANEL

CONTROL PANEL

Figure 1-2 shows the front of the optional control

TABLE 1-1. SYMBOLS

SYMBOL DESCRIPTION


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Display Menu Selection Buttons

Four momentary soft-key buttons are used to stepthrough the various menus and to adjust parame-

ters. These selection buttons are active when aword or symbol in the graphical display is shownabove the button. Some submenus do not includeany active buttons.

The function of the four selection buttons varieswith each menu.

When the symbol is displayed, theselection button can be used to switch to

Automode.

When the symbol is displayed, the selec-tion button can be used to switch to ManualRunmode.

When the up and down triangles ( and )are displayed, the selection buttons are usedto navigate between a series of submenus.

NOTE: When any Operator menu is dis-played, a series of Service menus canbe viewed by simultaneously pressingthe and selection buttons for twoseconds (see page1-20).

tor menu that was displayed before the Autoor Manual Run mode was selected.

When ADJUSTis displayed, the selection

button is used to display an adjustablemenu. When the ADJUST button is pressed,the first adjustable parameter or value in thesubmenu is highlighted.

When the symbol is displayed, theselection button is used to navigate to aneditable field within a menu.

When the +and symbols are displayed,

the selection buttons are used to increase ordecrease a parameter or value shown on thescreen.

When changing values, pressing the buttonbelow the + symbol increase the value andpressing the button below the symbol de-creases the value.

When SAVEis displayed, the selection but-ton is used to save changes made in a sub-menu. If the Previous Menu button ispressed before pressing SAVE, thechanges are not saved.

Some menus include a list of numbered sub-


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Previous Main Menu Button

Press the button to view the previous mainmenu.

NOTE: In the Screen Adjust menu, settings are not

saved when the button is pressed.

OFFBUTTON

If the button is pressed during genset operation(manual or remote start), the engine immediatelyshuts down and the control enters the Off mode. Ifpossible, this hot shutdown should be avoided to

help prolong the reliability of the genset.

Not In Auto Indicator

This red lamp is lit when the control is not in theAuto mode.

Shutdown Indicator

This red lamp is lit when the control detects a Shut-down condition. The generator set cannot bestarted when this lamp is on. After the condition iscorrected, the lamp can be reset by performing afault reset. When Battle Short mode is enabled andan overridden shutdown fault occurs, the Shut-down lamp is lit even though the genset continuesto run.

Warning IndicatorThis yellow lamp is lit whenever the control detectsa warning condition. This lamp is automaticallyshut off when the warning condition no longer ex-ists.

R S I di


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CONTROL PANEL SYSTEM MESSAGES

A system pop-up message is displayed when theevent it is displaying becomes active. These pop-

up messages remain displayed until pre-empted byanother pop-up message or until the or thedisplay buttons is pressed or the event has expired.

Once the or the button is pressed, the pre-vious screen is redisplayed.

Communication Messages

System messages are displayed for initial power-

up or when there is a subsequent loss of commu-nications. Auto and Manual Run modes can also beselected when communication messages are dis-played (for more information, see page 1-18).

Upon initial power-up, the message Establishingcommunication with control is displayed (see Fig-ure 1-4). This menu also displays the screens soft-ware number and version.

SCRN PN03266796 V#.##

until communications have been re-established(see Figure 1-5). The LEDs then return to the statedetermined by the control.

FIGURE 1-5. RE-ESTABLISHINGCOMMUNICATIONS MESSAGE

If either communication message remains dis-played (cannot view other menus), this is an in-dication that communications between thecontrol panel and the control board is lost. Con-tact an authorized service center for service.

Event Messages

When pre-set events (start or stop) are activated,Event messages are displayed showing the timeremaining until the event occurs (see Figure 1-6).


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Status Messages

Status messages for some events are displayed onthe optional control panel with a code number but

are not announced with a lamp indicator. Text sta-tus messages include the event code, a short de-scription, and the time the event occurred. Symbol-ic status messages include the event code andsymbols to indicate the type of event that occurred.

On Full Authority Electronic engines, the enginecontroller saves data after each run. During thistime, the display displays the message shown in

Figure 1-7. The generator can still be started whilethe ECM Datasave is in progress.

FIGURE 1-7. DATASAVE STATUS MESSAGE

Shutdown faults can also be acknowledged whenin Auto mode by using an external customer-sup-plied remote fault reset switch. This ability must beenabled by setting the Remote Fault Reset En-

abled trim to Enabled (disabled by default) usingInPower.

The remote fault reset switch must be wired intoone of the four configurable inputs. The chosenconfigurable input should have its function mappedto the Fault Reset function. To reset the fault, theremote start command must be removed prior tothe remote fault reset switch being activated.

Faults are removed from the display when they arecleared.

NOTE: Pressing the or button also clears thefault from the front panel display.

Faults are re-announced if they are detected againafter being acknowledged.

Fault= WARNINGor SHUTDOWN


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FAULT/STATUS CODES

Table 1-2provides a list of fault and status codes,types, displayed messages/symbols, descriptions,

and fault categories (CTG).

Category A Fault Codes:Pertain to engine or al-ternator shutdown faults that require immediate re-pair by trained and experienced service personnel(generator set non-operational). The control pre-vents the generator set from being restarted if ashutdown fault is not corrected.

Category B Fault Codes:Consist of faults thatcan affect generator set performance or can cause

engine, alternator, or connected equipmentdamage. Operate the genset only when it is power-ing critical loads and cannot be shut down. Catego-ry B faults require repair by trained and experi-

enced service personnel.

Category C Fault Codes:Consist of faults that arerepairable by site personnel. Service will be re-quired by trained and experienced service person-nel if site personnel cannot resolve the problem.

Category D Fault Codes: Indicates non-criticaloperational status of generator set, external faults,

or customer fault inputs. These faults require repairby trained and experienced service personnel.

TABLE 1-2. FAULT AND STATUS CODES

DISPLAYED MESSAGE/SYMBOLS

CTG CODE LAMPTEXT VERSION

SYMBOLICVERSION

DESCRIPTION

C 115**Shutdown

HIGH COOLANTTEMP 115

Indicates that the engine coolanttemperature is above normal and hasreached the shutdown trip point.

A 121 Shutdown SPEED SIGNALLOST

121Indicates that no magnetic pickup pulseswere sensed for a Loss of Speed delay. Ifa magnetic pickup is disabled, this fault isnot activated.


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TABLE 1-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION


LAMPCODECTG DESCRIPTIONSYMBOLIC

VERSION

TEXT VERSIONLAMPCODE

C 359 Shutdown FAIL TO START

359The genset has failed to start after a setnumber of crank attempts. This indicates apossible fuel system problem (enginecranks but fails to start).

A 415** Shutdown LOW OILPRESSURE 415

Indicates the engine oil pressure hasdropped below normal and has reachedthe shutdown trip point.

C 441** Warning LOW BATTERY

441Indicates battery voltage supply to the

control is approaching a low level at whichunpredictable operation can occur.

C 442** Warning HIGH BATTERY

442Indicates battery voltage supply to thecontrol is approaching a high level atwhich damage to the control can occur.

B 1123*

Shutdown SHUTDOWNAFTER BS 1123

A shutdown fault occurred while the BattleShort mode was enabled.

C 1131*

Warning BATTLE SHORTACTIVE

1131Indicates that the control is in Battle Shortmode

used to bypass several fault

shutdowns for genset operation duringemergencies.

D 1311 Configur-able

Customer FaultInput 1 1311

The nature of the fault is an optionalcustomer selection.


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CTG DESCRIPTION


LAMPCODECTG DESCRIPTIONSYMBOLICVERSION


C 1435**

Warning LOW COOLANTTEMP

1435

Indicates that the engine coolanttemperature is below the adjustedsetpoint. This may indicate that thecoolant heater is not operating or is notcirculating coolant.

C 1438 Shutdown FAIL TO CRANK

1438The genset has failed to sense rotation fortwo start attempts. This indicates apossible fault with the control, speed

sensing, or the starting system.

C 1442**

Warning WEAK BATTERY 1442Indicates that the genset battery voltage isbelow battery thresholds during cranking.

A 1446**

Shutdown HIGH ACVOLTAGE

1446

Indicates that the one or more measuredAC output voltages has exceeded thethreshold for longer than a specified timelimit. The threshold and time limits are130% of nominal for 0 seconds or 110% of

nominal for 10 seconds.

A 1447**

Shutdown LOW ACVOLTAGE

1447

Indicates that the measured AC outputvoltage is below the threshold for longerthan a specified time limit. The thresholdand time limits are 85% of nominal for 10seconds.


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CTG DESCRIPTION


LAMPCODECTG DESCRIPTIONSYMBOLICVERSION


D 1944 Warning ANNUNCIATOROUTPUT CON-FIGURATIONERROR

1944Indicates a mismatch in the configurationof one of the annunciator relay outputs.

A 2335 Shutdown EXCITATIONFAULT 2335

Indicates that a loss of voltage orfrequency sensing from the generator hasoccurred.

C 2676 Shutdown ALTERNATORFREQUENCYCONFLICT

Indicates the measured alternator line

frequency and measured alternatorexcitation frequency do not agree.

B 2677 Shutdown FAIL TO STOP

2677The genset continues to run afterreceiving a stop command from thecontroller.

A 2972**

Shutdown FIELDOVERLOAD 2972

Indicates that the Field Voltage has beenabove 70V for 8 seconds.

B 2678**

Warning CHARGERFAILURE

2678

Indicates the battery charging alternatorhas not reached a acceptable voltagerange within the selected time period(default = 120 seconds).

This warning is also displayed if youralternator is a type that does not supportthe controls charging alternator logic


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ADJUSTING DEFAULT SETTINGS

The optional control panel can be set up to displaywith SAE or SI units of measurement.

For more information, see the Adjust Screen menushown on page 1-26.

SAVING YOUR CHANGES

All adjustments made to menus are temporary untilthe SAVEbutton is pressed. If the SAVE button ispressed and the engine is running, the adjustmentsare not saved until after the engine speed is zero. If

power is lost to the control before a SAVE is execut-ed, all temporary adjustments are lost.

Adjustments to the following are stored in flashmemory in the optional display panel.

Contrast

Brightness

Units

Local or remote display

Symbols or text displayed

Access code required for mode change toAuto or Manual Run

Auto / Manual Off switch status

OPERATOR MENUS

Figures 1-10and 1-11show block representationsof the following Operator menus.

Engine Status

Alternator Status

Line-to-Line Voltage

Line-to-Neutral Voltage

Alternator Amperage

To navigate between the Operator menus, press

the buttons next to the and symbols in thegraphical display.

The Operator menus can be used to select Auto orManual Run modes (see page 1-18).

Engine Status Menu

This menu displays the engine starting battery volt-age, engine coolant temperature, engine oil pres-

sure, and hours of engine operation.

Alternator Status Menu

This menu displays genset load (in kVA), frequen-cy, and engine speed (RPM).


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OPERATOR MENUS Text Version

THREE PHASEONLY SINGLE

PHASEONLY


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OPERATOR MENUS Symbolic Version

THREE PHASEONLY SINGLE

PHASEONLY


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SELECTING AUTO, MANUAL RUN, ANDOFF MODES

Auto, Manual Run, and Off modes can be selected:

From any of the Operator menus

When the message Establishing commu-nication with control is displayed

When the message Re-establishing com-munication with control is displayed

Switching to Auto, Manual Run, or Off mode can be

restricted to authorized personnel. If a control pan-el is set up with the mode change access code fea-ture enabled, an access code must first be enteredbefore the mode can be changed. The modechange access code feature is enabled through theDisplay Setup submenu (see page 1-14).

The Auto or Off mode switch status is saved in non-volatile memory when it changes. When the control

panel powers up (after sleeping or upon battery re-moval), the switch status is restored to its previoussaved state.

Entering the Mode Change Access Code

If th d h f t d i

2. Press the arrow selection button to moveto the next numeric character.

3. Press the button below the + or symbols untilthe value reads 2.

4. Press the arrow selection button to moveto the next numeric character.

5. Press the button below the + or symbols untilthe value reads 1.

6. After you have completed entering the pass-word, press the arrow selection button .

NOTE: If an incorrect password is entered,the Operator menu that was displayedbefore Auto, Manual Run, or Off modewas selected is redisplayed.

TEXT VERSION


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Selecting Auto Mode

To switch to Auto mode (see Figure 1-13),

1. Press the button on any of the Operator

menus or the Establishing/Re-establishingcommunication with control menus.

2. If the mode change access code feature is en-abled, the Mode Change Access Code menuis displayed. Enter the mode change accesscode as described above.

3. A menu with alternating arrows is displayed

above a second symbol. Press the sec-

ond button. The Operator menu that wasdisplayed before Auto mode was selected isredisplayed.

To disable Auto mode, press the button.

NOTE: Manual Run mode can also be selected

while in Auto mode.

ALTERNATINGARROWS ARE

DISPLAYED

THIS MENU ISDISPLAYED ONLY IFTHE MODE CHANGE

ACCESS CODE

FEATURE IS ENABLED


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Selecting Manual Run Mode

To switch to Manual Run mode (see Figure 1-14),

To switch to Manual Run mode,

1. Press the button on any of the Operator me-nus or the Establishing/Re-establishing com-munication with control menus.

2. If the mode change access code feature is en-abled, the Mode Change Access Code menu

is displayed. Enter the mode change accesscode as described on the previous page.

3. A menu with alternating arrows is displayed

above a second symbol. Press the second

button. The Operator menu that was dis-played before Manual Run mode was selectedis redisplayed.

To disable Manual Run mode, press the button.

NOTE:Auto mode can also be selected while inManual Run mode. Switching to Auto modemay result in the generator set shutting

ALTERNATINGARROWS AREDISPLAYED

THIS MENU ISDISPLAYED ONLY IFTHE MODE CHANGE

ACCESS CODE

FEATURE IS ENABLED


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SERVICE MENUS

Figure 1-15shows a block representation of themenus available from the Service Menus.

The first Service Menu can be viewed from any ofthe Operator menus by simultaneously pressingthe and selection buttons for two seconds.The first Service Menu provides access to the fol-lowing menus:

Setup Menus Used by Service personnel.Adjusting the Setup menus is restricted by apassword. To view the Setup menus only,

press the VIEW button on the Setup pass-word menu.

History / About see page1-22

Screen Adjust see page 1-26

To return to the Operator menu that was displayed

prior to viewing the Service Menu, press thebutton.

The second Service Menu can be viewed by press-ing the selection button on the first ServiceMenu. The second Service Menu provides accessto the following menus:

Fault History see page 1-24

The third Service Menu can be viewed by pressingthe selection button on the second ServiceMenu. The third Service Menu provides access tothe Network Status menus.

Status Menu

The Status menu is displayed when the (5)buttonis pressed on the second Service Menu. The Sta-tus menu shows the following:

Voltage regulator (drive) level, in percentageof duty cycle

Governor regulator (drive) level, in percent-age of duty cycle. This value is only dis-played if the governor is enabled.

Network Status Menus

The Network Status menus are displayed when the(7)button is pressed on the third Service Menu.

Two menu are used to display the quantity of thefollowing devices that are connected to the net-work.

Universal Annunciators

Bar graphs


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HISTORY / ABOUT MENUSSEE PAGE 1-22

SETUP MENUSSEE PAGE 1-4

SCREEN ADJUST MENUSEE PAGE 1-26

1ST

SERVICEMENU


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HISTORY / ABOUT MENUS

Figure 1-16shows a block representation of theHistory / About menu. The first History / About sub-menu is displayed when the (2)button is pressed

on the Service Menu (see Figure 1-15).

Press the buttons next to the and symbols inthe graphical display to navigate between the His-

tory / About submenus. Press the button to re-turn to the Service Menu.

History Submenu

This submenu displays the number of enginestarts, hours of operation for the engine, and hoursof operation for the control.

About Genset Submenus

Two submenus display the generator set modelnumber, control number, and genset applicationfrequency rating.

About Control Submenu

This submenu displays the controls part number,serial number (up to 11 characters), software partnumber (up to 9 characters), and software version.

About Display Submenu

This submenu displays the optional control panelsoftware part number, software version, screenpart number, and screen version of the display.


27/34

HISTORY / ABOUT MENUS


28/34

FAULT HISTORY MENU

Figure 1-18shows a block representation of theFault History menu. The first Fault menu is dis-played when the (4)button is pressed on the sec-

ond Service Menu (see Figure 1-15). If there areany active fault submenus, an Active Fault head-ing is displayed for the most recent active fault. Allother fault submenus display a Fault Historyheading. Five of the most recent faults can beviewed. An example of how a fault code is dis-played is shown in Figure 1-17.

Press the buttons next to the and symbols in

the graphical display to navigate between menus.

Press the button to return to the Service Menu.

Information on faults is included in Table 1-2onpage 1-10.

FAULTCODE

FAULTDESCRIPTION

TIME FAULTOCCURRED

FIGURE 1-17. FAULT HISTORY MENU EXAMPLE


29/34

FAULT HISTORY MENU

Fault 1

Fault 2

Active Fault

OR


30/34

SCREEN ADJUST MENU

Figure 1-19shows a block representation of theScreen Adjust menu. The Screen Adjust menu isdisplayed when the (3)button is pressed in the firstService Menu (see Figure 1-15).

Adjusting Values/Parameters

1. Press the ADJUSTselection button to selectthe first parameter or value to be changed.

2. Press the+orselection buttons to adjust val-ues or select parameters.

3. Press the arrow selection button to navi-gate to the next or previous adjustable value orparameter.

4. After adjusting values/selecting parameters,press the SAVEbutton to save your settings.

NOTE: If the Previous Menu button ispressed before pressing the SAVEbutton, the changes are not saved.

5. Press the button to return to the Service

Menu.

Screen Adjust Menu

This menu allows for adjusting the screens con-trast and brightness and for selecting the units ofmeasurement (SAE or SI) to be displayed.

Contrast and Brightness: Press the + or selection buttons to adjust the screens con-

trast and brightness. Changing the bright-ness setting also affects the brightness ofthe LEDs on the control panel.

Units:Press the +or selection buttons toselect SAE (F, PSI) or SI (C, kPa) units ofmeasurement to be displayed.

SCREEN ADJUST MENU

No. 630-327Rev. SysPCC 1302 OEM Genset

HMI2xxRun(Wakeup)

Auto

(C fi bl W k )

J2510

J2511

J29 6

J29 4


31/34

1-27

Modified 7/2

PCC1302 Baseboard

Alternator

Terminal Block

PMG(optional)

L1 L2 L3 LN

ShuntApplications

PMG Applications

+

LL600 VoltMax

Field Winding

20Amp

ConfigurableInput

#4, Fuel Level Switch(Wakeup)

ECM Engine Connection

Usealternatorcentertaps

ora transformerifLL voltage>240 VAC

J25 Display

Battery

+

Fused B+

B+Return

Switches OEM

connected OR

Terminalblocks forcustomer connections

FSOControl

EstopB+

Power

J20 14

Pilot Relay

Starter

Control

EstopB+

Power

J20 15

Switched B+

(Run) Control

EstopB+Power

J20 3

J20 1

Chassis Ground

BatteryChargingAlternator(ICRegulatorType/Kubota)

Battery Charger

AlternatorFlash/Failed J20

22

Lamp

FailedOutput

IC

RegulatorPower

BatteryChargingAlternator(NonICRegulatorType/Bosch)

Battery ChargerAlternator

Flash/FailedJ20 22Field

Flash

J20Genset

J20 9

J20 10

J20 20

J20 21

J20 2

J20 4

J20 7

J20 12

J18 1

J18 2

J18 3

10Amp

P2

P3

P4

J17 2

J17 1

J12 1

J12 4

J12

2

J12 5

J12 3

J12 6

J22 1

J22 2

J22 3

J22 4

J12Genset Current

J22Genset Voltage

5A

C T s ,

Switched

B+

J20 11

J20 18

J20 6

Input

Return

Configurable Input#3, Coolant Level

Switch

(Wakeup)

J20 17

J20 5

Input

Return

OR

OR

KeyswitchControlJ11 21

Pilot RelayEstopB+

Power

LS Out

J11Engine

J17AVR Control

J18 AVR Power

Switched

B+

LSOut

LSOut

LSOut

DriverRating:

4Amps

Peak: 6

Amps

Relay B+ internally

fusedat1.85AB.C.Alt. Flash

internallyfused at1.5A

ECM(PGI

Compliant)

Keyswitch

(FSO

optionally)

Some ECMsintegratethe FSO withthe

Keyswitch operation.

Use adedicated FSO ifapplication s ECM does

notprovide FSO

operation.

J1939 (+)

J1939 ()

J1939 (+)

J1939 ()

J1939(Shield)

120

Ohm120ohm terminated

Only terminate shield

ononeend

J11 20

J11 19

J11 17

UseL1/L2/N

for1phaseapplications

Don t connect

N inDelta

configuration

HMI Fused B+ and

Customer Fused B+

share acommon 4.5Afuse.

HMI FusedB+ is

assumedto consumeno morethan 1.5A

Partnumbers

J11 Mate:03232161

Sockets: 03232466

PartnumbersJ25 Mate:03232445

Sockets: 03232466


Sockets: 03232466

Partnumbers

J22Mate: 0323222603

Partnumbers

J12 Mate:03231932Sockets: 03231200

Partnumbers

J17 Mate:03232098Sockets: 03231200


Sockets: 03231200

Partnumbers

PCC1302: 0327161701

Fused B+

These signalsgotothe

display but

don t g o

throughthePCC controller.

Terminal

BlockJ20Harness

RemoteEstop

PB (B)

Basic

Customer

Fused B+

These signalsgo to the

engine but

don t go

throughthePCC controller.

Terminal

BlockJ20

Harness

Fused B+

Thesesignals

go to thegenset but

don t go

through thePCCcontroller.

Terminal

BlockJ11, J25Harness

Basic

Customer

EstopB+Power

Fused B+

LocalEstop

PB

Input (Wakeuponopen)

Return

J25 2

J25 6

Remote EstopPB (B)

A

B

Fused B+

orHMI3xxDisplay

HMI FuseB+

B+Return

PCCNetA(+)

PCCNet B ()

(ConfigurableWakeup)

System Wakeup

J254

J253

J255

J2512

J258

UseShielded Twisted Pair forPCCNet

Only terminate shield on one end

Partnumbers

HMI220:03006314

HMI320:

03006315J28 Mate:

03232091

J29 Mate:03232456

Sockets: 03232466

J29 1

J29 2

J29 3

J28 1

J28 2

HMI 114Bargraph

HMI Fuse B+

B+Return

PCCNetA (+)

PCCNetB ()SystemWakeup

J254

J253J255

J2512

J258

PartnumbersHMI114:

0300????J1 &J6 Mate:

03232011

Sockets: 03232466

J1 3

J1 4J1 5

J6 1

J6 2

Locate near

mounting screw

chassis.

HMI211Display

HMI Fuse B+

B+Return

PCC NetA (+)

PCCNet B ()

Manual (Wakeup)

Auto (Config urable Wake up)J1 6

J1 7

System Wakeup

J1 1

J1 2

J1 4

J1 3

J1 5

J2510

J2511

J254

J253

J255

J2512

J258

PartnumbersHMI211:

03006014

OR

Local

FIGURE 1-20. PCC 1302 WIRING (SHEEET 1 OF 4)

No. 630-3270 Sh 1Rev. Sys: ProEM difi d 7/2006PCC 1302 OEM Genset

HMI2xxRun (Wakeup)

Auto

(Configurable Wake up)

J2510

J2511

J29 6

J29 4


32/34

1-28

Modified 7/2006

LocalEstopPB

PCC1302 Baseboard

Alternator

Terminal Block

PMG(optional)

L1 L2 L3 LN

ShuntApplications

PMG Applications

+

LL 600VoltMax

Field Winding

AUX 104GOVERNOR POWER STAGE

Active OilPressureSender

UseShielded Twisted Pair forMagPU

OR

20Amp

ConfigurableInput

#4, Fuel Level Switch(Wakeup)

PCC 1302 OEM GensetHydromechanical Engine

Connection

Usealternatorcentertaps

ora transformer

i fLLvoltage>240 VAC

J25 Display

Input(Wakeup on open)

Return

J25 2

J25 6

Remote EstopPB(B)

Battery

+

Fused B+

B+Return

Switches OEMconnected OR

Terminalblocks forcustomer connections

FSOControl

EstopB+

PowerJ20 14

Pilot Relay

Starter

Control

EstopB+

Power

J20 15

Switched B+

(Run) Control

EstopB+Power

J20 3

J20 1

Chassis Ground

BatteryChargingAlternator(ICRegulatorType/Kubota)

Battery Charger

AlternatorFlash/Failed

J2022

Lamp

FailedOutput

ICRegulator

Power

BatteryChargingAlternator(NonICRegulatorType/Bosch)

Battery ChargerAlternator

Flash/FailedJ20 22Field

Flash

J20Genset

J20 9

J20 10

J20 20

J20 21

J20 2

J20 4

J20 7

J20 12

J18 1

J18 2

J18 3

10Amp

P2

P3

P4

J17 2

J17 1

J12 1

J12 4

J12 2

J12 5

J12 3

J12 6

J22 1

J22 2

J22 3

J22 4

J12Genset Current

J22Genset Voltage

5AC T s ,

Switched

B+

J20 11

J20 18

J20 6

Input

Return

Configurable Input

#3, Coolant LevelSwitch

(Wakeup)

J20 17

J20 5

Input

Return

J11 1+5V

J11 3Sense

J11 2Return

Passive OilPressureSender

J11 3Sense

J11 2Return

Coolant

TemperatureSensor

(OnanType)

J11 11Sense

J11 12Return

OR

OR

GlowPlug

ControlJ11 7

Pilot Relay

Ignition

ModuleControlJ11 7

J11 6

J11 6

ORRelay B+

Relay B+

LS Out

LS Out

J11 9+

J11 10

J11 8Shield

Mag

Pickup

J11Engine

J11 4

J11 5

OR

Governor PWM+

GovernorPWM

3rd Party

FuelActuatorModule

(20mAMax)

J11 4

J11 5 GovernorPWM+

Governor PWM

J1 2

J1 1 J1 4 Act. LS Driver

FuelActuator

(6 AmpsMax)

J1 3

J1 5Gov PSPower

J1

GovPS

A

B

J17AVR Control

J18 AVRPower

Switched

B+

LSOut

LSOut

LSOut

Driver

Rating:4Amps

Peak: 6

Amps

Relay B+ internallyfusedat 1.85A

OR

Low Oil Pressure

Switch

J11 3

J11 2

Input

Return

Relay B+in ternally

fusedat 1.85A

B.C.Alt. Flash

internally fused at

1.5A

UseL1/L2/Nfor1phase

applications

Don tconnect

N inDeltaconfiguration

HMI Fused B+andCustomerFused B+

share acommon 4.5Afuse.

HMIFusedB+isassumed to consume

nomore than1.5A

Partnumbers

J25 Mate: 03232445Sockets: 03232466

Partnumbers

J11 Mate: 03232161Sockets: 03232466

Partnumbers

J20 Mate: 03232446Sockets: 03232466

Partnumbers

J12 Mate: 03231932Sockets: 03231200

PartnumbersJ22Mate:0323 222603

Partnumbers

J17 Mate: 03232098Sockets: 03231200

Partnumbers

J18 Mate: 03232444

Sockets: 03231200

PartnumbersPCC1302:0327161701

PartnumbersAux 104: 03271507J1Mate:0323 2216: Sockets: 03231200

Fused B+

These signals

go to thedisplay but

don tgo

throughthe

PCC controller.

TerminalBlock

J20Harness

Remote Estop

PB(B)

Basic

Customer

Fused B+

Fused B+

These signals

gototheenginebut

don t go

through thePCC controller.

Terminal

BlockJ20

Harness

B+ Return J20

Harness

Fused B+

B+Return

Gov PS PowerFused B+

Fused B+

These signals

gotothegensetbut

don t gothrough the

PCC controller.

TerminalBlock

J11Harness

B+Return

J11,J25Harness

BasicCustomer

EstopB+ Power

or HMI3xxDisplay

HMI Fuse B+

B+Return

PCC NetA (+)

PCC Net B ()

(Configurable Wakeup)

System Wakeup

J254

J253

J255

J2512

J258

UseShieldedTwistedPairfor PCC NetOnlyterminate shieldon one end

Partnumbers

HMI 220:03006314

HMI 320:

03006315J28 Mate:

03232091J29 Mate:

03232456

Sockets: 03232466

J29 1

J29 2

J29 3

J28 1

J28 2

HMI 112Bargraph

HMI FuseB+

B+Return

PCCNetA (+)

PCCNetB ()SystemWakeup

J254

J253J255

J2512

J258

Part numbers

HMI 112:0300605002

J1& J6 Mate:

03232011Sockets: 03232466

J1 3

J1 4J1 5

J6 1

J6 2

Locate near

mounting screwchassis.

HMI211Display

HMI Fuse B+B+Return

PCCNetA (+)

PCCNetB()

Manual(Wakeup)

Auto (Confi gurable Wake up)J1 6

J1 7

System Wakeup

J1 1

J1 2J1 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)

No. 630-327Rev. SysModified 7/2PCC 1302 Customer Connections:

I npu t #1 I npu t #2Input #3 Input #4 Input #5 Input #6

System Wakeup TB15 5

RemoteStart TB110J1 7

Remote


33/34

1-29

Modified 7/2

PCC1302

Baseboard

BatteryCharger

Aux 101Remote I/O

CustomerFused B+

B+Return

CustomerFused B+

B+Return

PCC Net A(+)

PCCNetB ()

SystemWakeup

PCCNetA (+)

PCCNetB()

System Wakeup

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

HMI2xxandHMI3xxDisplay

CustomerFused B+

B+Return

PCC Net A(+)

PCCNetB ()

SystemWakeup

TB1 1

TB1 2

TB15 5

TB1 5

TB1 3

UseShieldedTwisted Pairfor PCC NetOnlyterminateshieldon one end,to

prevent groundloops

J1 3

J1 4

J1 5

J14 1J14 2

Discrete Input (Sense)

Return

Aux 101

Relay 1Output

J2 1

J2 3

Relay NO

J2 2 Relay ComRelayNC

Aux 101Relay 2

Output

J2 4

J2 6

Relay NO

J2 5 Relay Com

RelayNC

Aux 101Relay 3

Output

J2 7

J2 9

Relay NO

J2 8 Relay Com

RelayNC

Aux 101

Relay 4Output

J2 10

J2 12

Relay NO

J2 11 Relay Com

RelayNC

Aux 101

Relay 5Output

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 7Output

J4 1

J4 3

Relay NO

J4 2 Relay Com

RelayNC

Aux 101

Relay8Output

J4 4

J4

6

Relay NO

J4 5 Relay Com

RelayNC

J11 1

J11 2

AND/OR

J11 3

J11 4

+/5V Analog

Input

Sense

ReturnOil

TemperatureRTD

Sensor

J11 5Sense

J10 3Current source

AND/OR

J11 7

J10 4

p p

J11 9

J10 5

p

J11 11

J10 6

p

J10 9Current return

J11 6Sense return

J10 10

J11 8

J10 11

J11 10

J10 12

J11 12

Exhaust Stack

Temperature #1RTD

Sensor

Sense

Current source

Current return

Sense return

AmbientTemperature

RTDSensor

Sense

Current source

Current return

Sense return

FuelLevel

Sensor

RTDSensor

Sense

Current source

Current return

Sense return

Intake Manifold

TemperatureRTD

Sensor

SenseCurrent source

Current return

Sense return

05VAnalog Input

Sense

Sense return

038VAnalog

InputJ11 13Sense

J11 14Return

AND/OR

J11 15

J11 16

Input #7 Input #8

Gnd must bewired in

CustomerFused B+

DiscreteInput(Sense)

Return

Gnd must be

wired in

OR

OR

OR

OR

OR

OR

OR

DiscreteInput (Sense)

ReturnGnd must be

wiredin

Customer

Fused B+


Return

Gnd must bewiredin

OR

OR

DiscreteInput (Sense)

ReturnGnd must be

wiredin

CustomerFused B+


Return

Gnd must bewiredin

OR

OR

Aux 102Remote I/O

J5

J6

J1

Aux 102

Relay 9Output

J1

1

J3 1

Relay NOJ2 1 Relay Com

RelayNC

Aux 102Relay 10

Output

J1 2

J3 2

Relay NO

J2 2 Relay Com

RelayNC

Aux 102

Relay 11Output

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

Relay13Output

J1 5

J3 5

Relay NO

J2 5 Relay Com

RelayNC

Aux 102

Relay14

Output

J1 6

J3 6

Relay NO

J2 6 Relay Com

RelayNC

Aux 102

Relay15Output

J1 7

J3 7

Relay NO

J2 7 Relay Com

RelayNC

Aux 102Relay16

Output

J1 8

J3 8

Relay NO

J2 8 Relay Com

RelayNC

J2

J3

Chassis Ground

Mounting screw

Maximumof 2Aux101 &

102s canbe used

pergenset

J11

J10

J4

J3

J2

TB 15

Usea local,floating(nongrounded)DCpowersupplyifB+ linehashigh

resistance(>1 ohm)due tolong runs,toprevent brief poweroutages during

genset starts

PCCNet must use a daisy chain

topology only

HMI 113Annunciator

CustomerFused B+

B+Return

PCC Net A(+)

PCCNetB ()

TB1 1

TB1 2

TB1 5

TB1 3

HMI 112

Bargraph CustomerFused B+B+Return

PCC Net A(+)

PCCNetB ()

SystemWakeup

TB1 1

TB1 2

TB15 5

TB1 5

TB1 3

J23

J24

TB116

TB115

J15

J13

J1

4J61

J62

J4

J4 1

J4 2

Input

ReturnInput #9

J4 3

J4 4ReturnInput #10

Input

J4 5

J4 6ReturnInput #11

Input

J4 7

J4 8ReturnInput #12

InputJ10 7

J10 95VDCSupply#1

(20mA max)

+

Return

J10 8

J1010

5VDCSupply #2(20 mAmax)

+

Return

J10

Part numbersAux 101:

03271536

Part numbersAux 102:

03271265

Partnumbersw/oenclosure:

300592901w/enclosure:

300592902

PartnumbersHMI 112:0300605002

Aux 102

Relay OutputRatings:

2A,30VDC,

250VAC

Aux 101Relay Output

Ratings:30VDC,

250VACNO: 5A

NC: 3A

AND/OR

AND/OR

PartnumbersAux 101 mates:

J1: 0323219204J14:0323167802

Others: comew/ boardAux 102 mates:

J1, J2, J3:0323167808J4: 0323167807

Others: comew/ board

Refer to the PCCNetSpec Sheet for

further detailson PCCNet

HMI211CustomerFused B+

B+Return

PCC NetA (+)

PCC Net B ()

TB1 1

TB1 2

TB1 5

TB1 3

J1 4J1 1J1 2

J1 3J1 5

Remote

Part numbers

HMI211:03006014

J29 3

J29 1

J29 2

J28 1

J28 2

FIGURE 1-20. PCC 1302 WIRING (SHEEET 3 OF 4)

No. 630-3270 Sh 1Rev. Sys: ProEModified 7/2006

PCC 1302 Customer Connections:


34/34

1-30

Modified 7/2006

PCC 1302 Baseboard

Relay Output

Ratings:3.5A,

30VDC,

250VAC

Customer

Output#1

TB1 6 Relay NO

TB1 7 Relay Com

See Application Notessection for high level

Estopcircuit

TB1 Basic

TB1 11

TB1 10

Input

Return

Remote

Start

(Wakeup)TB1

12

TB1 13ReturnCustomer

Input #1

Input

TB1 14

TB1 15ReturnCustomer

Input #2

Input

TB1 5

TB1 10

Customer fused

Battery Supply

(3Amax)

+

Return

Customer

Output#2

TB1 8 Relay NO

TB1 9 Relay Com

Battery

+

RemoteEstop

PB(Remove jumper

if not used)

Input (Wakeuponopen)

Return

TB1 16

TB1 15

EstopB+Power

A

B

Local EstopPB(B)

PCC NetDevices(See Customer

PCC Net page)

PCCNetA (+) RS485

PCCNetB () RS485

TB1 1

TB1 2

PCC NetB ShieldTB1 3

TB1 4Ready To

LoadOutputLowSide Driver

Itemsin dashed lines

represent internal

PCC circuitry.

SystemWakeupTB15 5

TB15 Modbus/PC Tool

Modbus

SystemWakeup:

Groundif the PCC

control system is to

always stayawake.

(+)

()

RS485 (+)

RS485 ()

Shield

120

Ohm120 ohmterminated

Only terminateshield

onone end

TB15 3

TB15 4

TB15 1

PCC NetDevices(See Customer PCC Net page)

PCTool HarnessPC Tool

OR

Partnumbers

TB15 Mate: 0323219204

Partnumbers

TB 8 Mate:0323232503

Partnumbers

TB1 Mate: 03232434

Part numbers

PCTool Harness kit:05411199

EstopB+Power

These signals

go to the

customer but

don t go

through the

PCC controller.

Terminal

BlockJ20

Harness

Local EstopPB

(B)

J25

Harness

FIGURE 1-20. PCC 1302 WIRING DIAGRAM (SHEET 4 OF 4)

pcc1302 operator instructions

Documents

auto mode

control submenu

sleep mode

andthe control

manual run modewhen

optional control pan

battle short mode

additional control panelcan