Aux101 102

Owner Manual
Controller
AUX 101
AUX 102
English - Original Instructions11-2010 A030K737 (Issue 2)

Table of Contents
1. SAFETY PRECAUTIONS .............................................................................................................. 1
2. INTRODUCTION............................................................................................................................ 5
2.1 About This Manual.................................................................................................................. 5
2.2 About the AUX 101 ................................................................................................................. 5
2.3 About the AUX 102 ................................................................................................................. 5
2.4 About the Numbering of AUX 102 Inputs and Outputs........................................................... 6
3. CHARACTERISTICS OF THE AUX 101 AND AUX 102 WITH VARIOUS CONTROLLERS........ 7
3.1 Characteristics of the AUX 101 and AUX 102 with the PCC 1301, PCC 1302, and
PowerCommand 1.x................................................................................................................ 7
3.2 Characteristics of the AUX 101 and AUX 102 with the PCC 2100....................................... 10
3.3 Characteristics of the AUX 101 and AUX 102 with the PowerCommand 2.x and 3.x.......... 12
4. HARDWARE ................................................................................................................................ 19
4.1 AUX 101 Board..................................................................................................................... 19
4.2 AUX 102 Board..................................................................................................................... 27
4.3 How to Install the AUX 101/102 Hardware ........................................................................... 31
5. CONFIGURATION OF THE AUX 101 AND AUX 102 WITH VARIOUS CONTROLLERS ......... 39
5.1 Tools to Configure a PCC 1301 or PowerCommand 1.x AUX 101/102 ............................... 39
5.2 Tools to Configure a PCC 2100 AUX 101/102 ..................................................................... 44
5.3 Tools to Configure a PowerCommand 2.x or 3.x AUX 101/102 ........................................... 45
6. MANUFACTURING FACILITIES.................................................................................................. 49
APPENDIX A. WIRING DIAGRAMS ................................................................................................. 51
A030K737 (Issue 2) i
Table of Contents 11-2010
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ii A030K737 (Issue 2)
1 Safety Precautions
SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be
followed during installation and maintenance of the generator set and batteries.
Before operating the generator set (genset), read the Operator's Manual and become familiar
with it and the equipment. Safe and efficient operation can be achieved only if the
equipment is properly operated and maintained. Many accidents are caused by failure to
follow fundamental rules and precautions.
The following symbols, found throughout this manual, alert you to potentially dangerous
conditions to the operator, service personnel, or the equipment.
DANGER: This symbol warns of immediate hazards which will result in severe
personal injury or death.
WARNING: This symbol refers to a hazard or unsafe practice which can result in severe
personal injury or death.
CAUTION: This symbol refers to a hazard or unsafe practice which can result in personal
injury or product or property damage.
FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result from improper practices.
· DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine
compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.
· DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition
source near the generator set or fuel tank.
· Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine
should be made with an approved flexible line. Do not use zinc coated or copper fuel lines
with diesel fuel.
· Natural gas is lighter than air, and will tend to gather under hoods. Propane is heavier than
air, and will tend to gather in sumps or low areas. NFPA code requires all persons handling
propane to be trained and qualified.
· Be sure all fuel supplies have a positive shutoff valve.
· Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries
emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY

· Provide an adequate exhaust system to properly expel discharged gases away from
enclosed or sheltered areas and areas where individuals are likely to congregate. Visually
and audibly inspect the exhaust for leaks daily or per the maintenance schedule. Make
sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to
heat a compartment.
· The exhaust vent should be high enough to help clear gases, avoid accumulation of snow,
and in accordance with local mechanical codes.
· Be sure the unit is well ventilated.
A030K737 (Issue 2) 1
1. Safety Precautions 11-2010
· Engine exhaust and some of its constituents are known to the state of California to cause
cancer, birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

· Keep your hands, clothing, and jewelry away from moving parts.
· Before starting work on the generator set, disconnect battery charger from its AC source,
then disconnect starting batteries, negative (-) cable first. In lean-burn natural gas (LBNG)
gensets, also make sure the starter's air supply line is disconnected or completely vented
until the generator set is ready to start. This will prevent accidental starting.
· Make sure that fasteners on the generator set are secure. Tighten supports and clamps,
keep guards in position over fans, drive belts, etc.
· Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on
electrical equipment. Loose clothing and jewelry can become caught in moving parts.
· If adjustment must be made while the unit is running, use extreme caution around hot
manifolds, moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and death. Do not operate a genset where a
flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air intake and stop the engine. The
owners and operators of the genset are solely responsible for operating the genset safely.
Contact your authorized Cummins Power Generation distributor for more information.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

· Remove electric power before removing protective shields or touching electrical equipment.
Use rubber insulative mats placed on dry wood platforms over floors that are metal or
concrete when around electrical equipment. Do not wear damp clothing (particularly wet
shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear
jewelry. Jewelry can short out electrical contacts and cause shock or burning.
· Use extreme caution when working on electrical components. High voltages can cause
injury or death. DO NOT tamper with interlocks.
· Follow all applicable state and local electrical codes. Have all electrical installations
performed by a qualified licensed electrician. Tag and lock open switches to avoid
accidental closure.
· DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This
creates a potential for electrocution or property damage. Connect only through an
approved isolation switch or an approved paralleling device.
MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)

· Medium voltage acts differently than low voltage. Special equipment and training is
required to work on or around medium voltage equipment. Operation and maintenance
must be done only by persons trained and qualified to work on such devices. Improper use
or procedures will result in severe personal injury or death.
2 A030K737 (Issue 2)
11-2010 1. Safety Precautions
· Do not work on energized equipment. Unauthorized personnel must not be permitted near
energized equipment. Due to the nature of medium voltage electrical equipment, induced
voltage remains even after the equipment is disconnected from the power source. Plan the
time for maintenance with authorized personnel so that the equipment can be de-energized
and safely grounded.
GENERAL SAFETY PRECAUTIONS

· Coolants under pressure have a higher boiling point than water. DO NOT open a radiator
or heat exchanger pressure cap while the engine is running. To prevent severe scalding,
let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not
open it fully until the pressure has been relieved.
· Used engine oils have been identified by some state or federal agencies as causing cancer
or reproductive toxicity. When checking or changing engine oil, take care not to ingest,
breathe the fumes, or contact used oil.
· Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible
materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10).
· Make sure that rags or combustible material are not left on or near the generator set.
· Make sure generator set is mounted in a manner to prevent combustible materials from
accumulating under or near the unit.
· Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can
cause overheating and engine damage which present a potential fire hazard.
· Keep the generator set and the surrounding area clean and free from obstructions.
Remove any debris from the set and keep the floor clean and dry.
· Do not work on this equipment when mentally or physically fatigued, or after consuming
any alcohol or drug that makes the operation of equipment unsafe.
· Substances in exhaust gases have been identified by some state or federal agencies as
causing cancer or reproductive toxicity. Take care not to breath or ingest or come into
contact with exhaust gases.
· Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set.
A fire or explosion could result.
· Wear hearing protection when near an operating generator set.
· To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo
charger system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
DISPOSE OF THIS UNIT PROPERLY
A030K737 (Issue 2) 3
1. Safety Precautions 11-2010
4 A030K737 (Issue 2)
2 Introduction
2.1 About This Manual
This manual provides basic information about the AUX 101 and AUX 102. It explains how to
install the AUX 101 and AUX 102 and how to configure various controllers to use them. This
manual also provides reference information that can be used in advanced applications and in
troubleshooting.
2.2 About the AUX 101

The PowerCommand AUX 101 provides additional inputs and additional outputs for auxiliary
control and monitoring of the power system.
2.2.1 Number of Additional Inputs and Outputs on the AUX 101

TABLE 1. NUMBER OF ADDITIONAL INPUTS AND OUTPUTS ON THE AUX 101
Description Value
Number of Additional Inputs 8
Number of Additional Outputs 8
2.2.2 About AUX 101 Inputs

An AUX 101 input can be associated with a fault code. When the input is active, the fault is
active. When the input is inactive, the fault is inactive, though the fault might have to be reset.
Alternatively, some AUX 101 inputs can be assigned specific input functions instead of a fault
code. These functions have a variety of effects and vary by controller.
2.2.3 About AUX 101 Outputs

Each AUX 101 output is associated with a fault code. When the fault is active, the output is
active. When the fault is inactive, the output is inactive.
2.3 About the AUX 102

The PowerCommand AUX 102 provides additional inputs and additional configurable outputs for
auxiliary control and monitoring of the power system.
NOTE: The AUX 102 requires the AUX 101.
2.3.1 Number of Additional Inputs and Outputs on the AUX 102

TABLE 2. NUMBER OF ADDITIONAL INPUTS AND OUTPUTS ON THE AUX 102
Description Value
A030K737 (Issue 2) 5
2. Introduction 11-2010
Number of Additional Inputs 4

Number of Additional Outputs 8
2.3.2 About AUX 102 Inputs

An AUX 102 input can be associated with a fault code. When the input is active, the fault is
active. When the input is inactive, the fault is inactive, though the fault might have to be reset.
Alternatively, some AUX 102 inputs can be assigned specific input functions instead of a fault
code. These functions have a variety of effects and vary by controller.
2.3.3 About AUX 102 Outputs

Each AUX 102 output is associated with a fault code. When the fault is active, the output is
active. When the fault is inactive, the output is inactive.
2.4 About the Numbering of AUX 102 Inputs and

Outputs
The AUX 102 requires the AUX 101. As a result, many operator panels and software programs
start numbering AUX 102 inputs and outputs at 9 instead of 1. For example, AUX 102 output 1
may be referred to as AUX 102 output 9, output 9, or even AUX 101 output 9. All of these
expressions refer to the same output.
6 A030K737 (Issue 2)
3 Characteristics of the AUX 101 and
AUX 102 with Various Controllers
You should be familiar with the characteristics of the AUX 101 and AUX 102 before you attempt
to install them. The characteristics vary by controller.
3.1 Characteristics of the AUX 101 and AUX 102 with

the PCC 1301, PCC 1302, and PowerCommand 1.x
3.1.1 Maximum Number of AUX 101/102 for the PCC 1301, PCC
1302, and PowerCommand 1.x
TABLE 3. MAXIMUM NUMBER OF AUX 101/102 FOR THE PCC 1301, PCC 1302, AND
POWERCOMMAND 1.X
Description Value
Maximum Number of AUX 101 1
3.1.2 Required Part Numbers for Operator Panel Software to

Support the AUX 101
TABLE 4. REQUIRED PART NUMBERS FOR OPERATOR PANEL SOFTWARE TO SUPPORT THE
AUX 101
Software Part Number

Operator panel software 326-6652 (limited)
326-6333
3.1.2.1 How to Determine the Part Number of the Operator Panel Software
Use the History/About menus to determine the part number of the operator panel software.
The part number of the operator panel software is also displayed when the message
"Establishing communication with control" is displayed during startup.
3.1.2.2 Configuration Limitations in Operator Panel Software Version

0326-6652
If the operator panel is running software part number 0326-6652, the operator panel can only
configure the event type and display text for AUX 101 inputs 1-8 that are active-low. The
operator panel cannot configure AUX 101 outputs, an AUX 102, or other types of AUX 101
inputs 1-8.
Other versions of the operator panel allow for complete configuration of both the AUX 101 and
AUX 102.
A030K737 (Issue 2) 7
3. Characteristics of the AUX 101 and AUX 102 with Various Controllers 11-2010
NOTE: The software uses Active High and Active Low, but the hardware connection
is really Active Open and Active Closed, respectively. This section uses
Active High and Active Low to be consistent with the software. Make sure the
hardware is connected appropriately.
3.1.2.3 How to Upgrade Software on the AUX 101

1. Go to the InCal web site to get the latest software for the controller, operator panel, and
AUX 101.
2. Upgrade the software on the controller and on the operator panel, based on the instructions
provided with them.
3. Use InPower to upgrade the software in the AUX 101.
3.1.3 Possible Functions of AUX 101 Inputs for PCC 1301, PCC
TABLE 5. POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR PCC 1301, PCC 1302, AND
POWERCOMMAND 1.X
Input Possible Functions

1 Switch (active-high or active-low), voltage bias
2 Switch (active-high or active-low), speed bias
3-6 Switch (active-high or active-low), exhaust temperature sender, ambient temperature sender, fuel
level sender, alternator temperature sender, intake manifold sender, oil temperature sender
7-8 Switch (active-high or active-low)
3.1.3.1 Default Functions of AUX 101 Inputs for PCC 1301, PCC 1302, and
PowerCommand 1.x
All AUX 101 inputs are disabled.
3.1.3.2 PCC 1301 Fault Codes Generated by AUX 101 Switch Inputs
TABLE 6. PCC 1301 FAULT CODES GENERATED BY AUX 101 SWITCH INPUTS
Input Fault Code

Event Warning Shutdown
1 163 226 84
2 164 227 85
3 165 228 86
4 166 229 87
5 167 230 88
6 168 231 89
8 A030K737 (Issue 2)
11-2010 3. Characteristics of the AUX 101 and AUX 102 with Various Controllers
7 169 232 90
8 170 233 91
3.1.4 Default Functions of AUX 101 Outputs with the PCC 1301,
PCC 1302, and PowerCommand 1.x
TABLE 7. DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE PCC 1301, PCC 1302, AND
POWERCOMMAND 1.X
Output Default Function

1 Low oil pressure
2 High engine temperature
3 Charger AC failure
4 Battery (low, weak, or high)
5 Overspeed
6 Fail to start
7 Not in auto
8 Run
3.1.4.1 About AUX 101 Output 4

AUX 101 output 4 can be associated with up to three fault codes. If any of the fault codes are
active, the output is active. If none of the fault codes are active, the output is inactive.
3.1.5 Possible Functions of AUX 102 Inputs for PCC 1301, PCC
TABLE 8. POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR PCC 1301, PCC 1302, AND
POWERCOMMAND 1.X

9-12 Active-low switch
3.1.5.1 Default Functions of AUX 102 Inputs for PCC 1301, PCC 1302, and
PowerCommand 1.x
A030K737 (Issue 2) 9
3.1.5.2 PCC 1301 Fault Codes Generated by AUX 102 Switch Inputs
TABLE 9. PCC 1301 FAULT CODES GENERATED BY AUX 102 SWITCH INPUTS
Input Fault Code

Event Warning Shutdown
9 171 234 92
10 172 235 93
11 173 236 94
12 174 237 95
3.1.6 Default Functions of AUX 102 Outputs with the PCC 1301,
PCC 1302, and PowerCommand 1.x
TABLE 10. DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE PCC 1301, PCC 1302, AND
POWERCOMMAND 1.X

9 Pre-low oil pressure
10 Pre-high engine temperature
11 Low coolant level*
12 Low fuel level*
13 Low coolant temperature
14 Common alarm
15 Not defined
16 Not defined
* - These are the default settings if the PCC 1301 Customer Inputs are defined as Low Coolant
Level or Low Fuel Level. By default, the PCC 1301 Customer Inputs are defined in this manner.

the PCC 2100
3.2.1 Maximum Number of AUX 101/102 for the PCC 2100
TABLE 11. MAXIMUM NUMBER OF AUX 101/102 FOR THE PCC2100
Description Value
Maximum Number of AUX 101 2*
Maximum Number of AUX 102 2*
* - The PCC 2100 does not support any additional inputs on the second AUX 101 or second
AUX 102. It only supports the additional outputs.
10 A030K737 (Issue 2)
3.2.2 Possible Functions of AUX 101 Inputs for PCC 2100

TABLE 12. POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR PCC 2100

1 Switch (active-high or active-low), voltage bias
2 Switch (active-high or active-low), speed bias
3-8 Switch (active-high or active-low)
3.2.2.1 Default Functions of AUX 101 Inputs for PCC 2100

3.2.3 Default Functions of AUX 101 Outputs with the PCC 2100
TABLE 13. DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE PCC 2100

1 Low oil pressure
3 Not defined
4 Battery (low, weak, or high)
5 Overspeed
6 Fail to start
7 Not in auto
8 Run
3.2.3.1 About AUX 101 Output 4

AUX 101 output 4 can be associated with up to three fault codes. If any of the fault codes are
active, the output is active. If none of the fault codes are active, the output is inactive.
3.2.4 Possible Functions of AUX 102 Inputs for PCC 2100

TABLE 14. POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR PCC 2100

9-12 Active-low switch
A030K737 (Issue 2) 11
3.2.4.1 Default Functions of AUX 102 Inputs for PCC 2100

3.2.5 Default Functions of AUX 102 Outputs with the PCC 2100
TABLE 15. DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE PCC 2100

11 Not defined
12 Not defined
13 Low engine temperature
14 Not defined
15 Not defined
16 Not defined

the PowerCommand 2.x and 3.x
3.3.1 Maximum Number of AUX 101/102 for the PowerCommand
2.x and 3.x
TABLE 16. MAXIMUM NUMBER OF AUX 101/102 FOR THE POWERCOMMAND 2.X AND 3.X
Description Value
3.3.2 Required Part Numbers to Support the AUX 101 for the
PowerCommand 2.x
TABLE 17. REQUIRED PART NUMBERS TO SUPPORT THE AUX 101 FOR THE POWERCOMMAND
2.X
Component Part Number

PCC 2300 base board A026N036
NOTE: PCC 2300 base board 0327-1636 does not support the AUX 101.
12 A030K737 (Issue 2)
3.3.3 Possible Functions of AUX 101 Inputs for PowerCommand

2.x and 3.x
TABLE 18. POSSIBLE FUNCTIONS OF AUX 101 INPUTS FOR POWERCOMMAND 2.X AND 3.X

1-2 Switch (active-open or active-closed)
3-6 Switch (active-open or active-closed), additional functions for configurable inputs, additional
functions for configurable analog inputs
7-8 Switch (active-open or active-closed)
3.3.3.1 Default Functions of AUX 101 Inputs for PowerCommand 2.x and
3.x
3.3.3.2 Additional Functions of Configurable Inputs on the

PowerCommand 2.x
Each configurable input can be mapped to one of these functions, instead of their default
function.
TABLE 19. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 2.X
Function Related Settings

Low Fuel in Day Tank Switch Low Fuel in Day Tank Time
Low Coolant Switch #2 None
High Alt Temperature Switch High Alternator Temperature Shutdown Threshold
(Aux101), High Alternator Temperature 1 Time (Aux101)
Ground Fault Switch Ground Fault Current Delay, Ground Fault Current
Threshold Percent
Exercise Switch Genset Exercise Time
Battle Short Switch Battle Short Enable
Battery Charger Failed Switch None
Low Engine Temperature Switch None
Speed Droop Enable Switch Speed Droop Percentage
Voltage Droop Enable Switch Voltage Droop Percentage
NOTE: Currently, Speed Droop Enable Switch and Voltage Droop Enable Switch are
not available, but they appear in the Operator Panel.
You can only map one configurable input to each of these functions. For example, there cannot
be two Battle Short Switches.
You can also set up a configurable input to do nothing at all.
A030K737 (Issue 2) 13
3.3.3.3 Additional Functions of Configurable Inputs on the

PowerCommand 3.x
function.
TABLE 20. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 3.X

Manual Run Switch None
Low Fuel in Day Tank Switch Low Fuel in Day Tank Time
Low Coolant Switch #2 None
High Alt Temperature Switch High Alternator Temperature Shutdown Threshold
(Aux101), High Alternator Temperature 1 Time (Aux101)
Ground Fault Switch Ground Fault Current Delay, Ground Fault Current
Threshold Percent
PTC Mode Switch See PTC settings.
Masterless Load Demand Enable Switch Not available
Predictive Load Enable Switch Not available
Ramp Load/Unload Switch Load Govern kVAR Ramp Load Time, Load Govern
kVAR Ramp Unload Time, Load Govern kW Ramp Load
Time, Load Govern kW Ramp Unload Time, Load Share
Ramp Load Time, Load Share Ramp Unload Time
Exercise Switch Genset Exercise Time
Battle Short Switch Battle Short Enable
Battery Charger Failed Switch None
Low Engine Temperature Switch None
Speed Droop Enable Switch Speed Droop Percentage
Voltage Droop Enable Switch Voltage Droop Percentage
NOTE: Masterless Load Demand Enable Switch and Predictive Load Enable Switch
are not available yet.
You can only map one configurable input to each of these functions. For example, there cannot
be two Battle Short Switches.
You can also set up a configurable input to do nothing at all.
3.3.3.4 Additional Functions of Configurable Analog Inputs on the

PowerCommand 2.x and 3.x
function.
TABLE 21. ADDITIONAL FUNCTIONS OF CONFIGURABLE ANALOG INPUTS ON THE

POWERCOMMAND 2.X AND 3.X
14 A030K737 (Issue 2)
Oil Temperature High Oil Temperature Threshold (Aux101), High Oil

Temperature Time (Aux101), Aux 101 Oil/Ambient/Intake
Manifold Temp Input Scaling Table, Aux101 Oil Temp
OOR Check Enable, Aux101 Oil/Ambient/Intake Manifold
Temp OOR High Limit, Aux101 Oil/Ambient/Intake
Manifold Temp OOR Low Limit, Aux101
Oil/Ambient/Intake Manifold Temp OOR Time
Exhaust Stack Temperature 1 Aux 101 Exhaust Stack Temp Input Scaling Table, High
Exhaust Stack Temperature 1 Threshold (Aux101), High
Exhaust Stack Temperature 1 Time (Aux101), Aux101
Exhaust Stack Temp 1 OOR Check Enable, Aux101
Exhaust Stack Temp OOR High Limit, Aux101 Exhaust
Stack Temp OOR Low Limit, Aux101 Exhaust Stack
Temp OOR Time
Exhaust Stack Temperature 2 Aux 101 Exhaust Stack Temp Input Scaling Table, High
Exhaust Stack Temperature 2 Threshold (Aux101), High
Exhaust Stack Temperature 2 Time (Aux101), Aux101
Exhaust Stack Temp 2 OOR Check Enable, Aux101
Exhaust Stack Temp OOR High Limit, Aux101 Exhaust
Stack Temp OOR Low Limit, Aux101 Exhaust Stack
Temp OOR Time
Ambient Temperature Ambient Temp Fault Delay, Ambient Temp Fault Level,
Ambient Temp Fault Threshold, Aux 101
Oil/Ambient/Intake Manifold Temp Input Scaling Table,
Aux101 Ambient Temp OOR Check Enable, Aux101
Oil/Ambient/Intake Manifold Temp OOR High Limit,
Aux101 Oil/Ambient/Intake Manifold Temp OOR Low
Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR
Time
Fuel Level Fuel Level 100 Percent Resistance (Aux101), Fuel Level
Zero Percent Resistance (Aux101), High Fuel Level
Threshold (Aux101), High Fuel Level Time (Aux101), Low
Fuel Level Threshold (Aux101), Low Fuel Level Time
(Aux101), Low Fuel Set/Clear Time, Very Low Fuel Level
Threshold (Aux101), Very Low Fuel Level Time (Aux101),
Aux101 Fuel Level OOR Check Enable, Aux101 Fuel
Level OOR High Limit, Aux101 Fuel Level OOR Low
Limit, Aux101 Fuel Level OOR Time
Alternator Temperature 1 High Alternator Temperature 1 Threshold (Aux101), High
Alternator Temperature 1 Time (Aux101), Aux101
Alternator Temperature OOR Check Enable, Aux101
Alternator Temperature OOR High Limit, Aux101
Alternator Temperature OOR Low Limit, Aux101
Alternator Temperature OOR Time
A030K737 (Issue 2) 15
Intake Manifold Temperature 1 High Intake Manifold Temperature 1 Threshold (Aux101),

High Intake Temperature 1 Time (Aux101), Aux 101
Oil/Ambient/Intake Manifold Temp Input Scaling Table,
Aux101 Intake Manifold Temp OOR Check Enable,
Aux101 Oil/Ambient/Intake Manifold Temp OOR High
Limit, Aux101 Oil/Ambient/Intake Manifold Temp OOR
Low Limit, Aux101 Oil/Ambient/Intake Manifold Temp
OOR Time
Drive End Bearing Temperature High Drive End Bearing Temperature Threshold
(Aux101), High Drive End Bearing Temperature Time
(Aux101), Aux101 Drive End Bearing Temperature OOR
Check Enable, Aux101 Drive/Non-Drive End Bearing
Temp OOR High Limit, Aux101 Drive/Non-Drive End
Bearing Temp OOR Low Limit, Aux101 Drive/Non-Drive
End Bearing Temperature OOR Time
Non-Drive End Bearing Temperature High Non-Drive End Bearing Temperature Threshold
(Aux101), High Non-Drive End Bearing Temperature Time
(Aux101), Aux101 Non-Drive End Bearing Temperature
OOR Check Enable, Aux101 Drive/Non-Drive End
Bearing Temp OOR High Limit, Aux101 Drive/Non-Drive
End Bearing Temp OOR Low Limit, Aux101
Drive/Non-Drive End Bearing Temperature OOR Time
You can only map one configurable analog input to each of these functions. For example, there
cannot be two Fuel Level inputs.
You can also set up a configurable analog input to do nothing at all.
3.3.3.5 PowerCommand 2.x and 3.x Fault Codes Generated by AUX 101
Switch Inputs
TABLE 22. POWERCOMMAND 2.X AND 3.X FAULT CODES GENERATED BY AUX 101 SWITCH
INPUTS
Input Fault Code

Device 0 Device 1
1 2619 2882
2 2621 2883
3 2622 2884
4 2623 2885
5 2624 2886
6 2625 2887
7 2626 2888
8 2627 2889
3.3.4 Default Functions of AUX 101 Outputs with the

TABLE 23. DEFAULT FUNCTIONS OF AUX 101 OUTPUTS WITH THE POWERCOMMAND 2.X AND
3.X
16 A030K737 (Issue 2)
1 Low oil pressure

3 Charger AC failure
4 Low battery voltage
5 Overspeed
6 Fail to start
7 Not in auto
8 Ready to load
3.3.5 Possible Functions of AUX 102 Inputs for PowerCommand

2.x and 3.x
TABLE 24. POSSIBLE FUNCTIONS OF AUX 102 INPUTS FOR POWERCOMMAND 2.X AND 3.X

9-12 Switch (active-open or active-closed), additional functions for configurable inputs
3.3.5.1 Default Functions of AUX 102 Inputs for PowerCommand 2.x and
3.x
3.3.5.2 PowerCommand 2.x and 3.x Fault Codes Generated by AUX 102
Switch Inputs
TABLE 25. POWERCOMMAND 2.X AND 3.X FAULT CODES GENERATED BY AUX 102 SWITCH
INPUTS
Input Fault Code

Device 0 Device 1
9 2628 2891
10 2629 2892
11 2631 2893
12 2632 2894
3.3.6 Default Functions of AUX 102 Outputs with the

TABLE 26. DEFAULT FUNCTIONS OF AUX 102 OUTPUTS WITH THE POWERCOMAND 2.X AND 3.X

11 Low coolant level
A030K737 (Issue 2) 17
12 Low fuel in day tank

13 Low coolant temperature
14 Common alarm
15 High battery voltage
16 Weak battery
18 A030K737 (Issue 2)
4 Hardware
4.1 AUX 101 Board
FIGURE 1. AUX 101 BOARD
4.1.1 AUX 101 S1

The S1 button can be used to change the AUX 101 device number.
4.1.2 AUX 101 Device Number Indicator

The AUX 101 device number indicator displays the device number of this particular AUX 101 in
a PCCNet network.
If there is only one AUX 101 in the PCCNet network, the device number must be zero (0).
If there is more than one AUX 101 in the PCCNet network, the device number of the first AUX
101 must be zero (0). The device number of any other AUX 101 cannot be zero, and it must be
unique in the PCCNet network.
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4.1.2.1 How to Change the AUX 101 Device Number

1. Press and hold the button S1 for at least five seconds. On the AUX 101 device number
indicator, a small dot should appear next to the current device number.
2. Press and release the button S1 until the desired number is displayed.
3. Wait five seconds. After five seconds of inactivity, the new device number is set, and the
small dot should disappear.
4. Disconnect and reconnect the AUX 101 J14 connector to cycle power to the AUX 101.
4.1.3 AUX 101 LEDs

TABLE 27. AUX 101 LEDS
LED (Color) Description

DS1 (green) This LED is on if the AUX 101 is connected to a PCCNet network and is operating normally.
DS2 (red) This LED is on if the AUX 101 is not connected to the PCCNet network.
DS3 (green) This LED is on if AUX 101 output 1 is active.
4.1.4 AUX 101 Connectors

TABLE 28. AUX 101 CONNECTORS
Connector Description
J1 Connection to controller
J2 AUX 101 outputs 1-4
J5 Connection to AUX 102
J10 Voltage sources, current sources
J11 AUX 101 inputs 1-8
J14 Power supply
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4.1.4.1 AUX 101 J1
FIGURE 2. AUX 101 J1
TABLE 29. AUX 101 J1
Pin Description
J1-1 Output power B-
J1-2 Output power B+
J1-3 PCCNet A
J1-4 PCCNet B
J1-5 System wakeup
4.1.4.2 AUX 101 J2
Pin Description
J2-1 AUX 101 output 1, normally-open contact
J2-2 AUX 101 output 1, common contact
J2-3 AUX 101 output 1, normally-closed contact
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4.1.4.2.1 AUX 101 Output 1-8 Specifications
TABLE 31. AUX 101 OUTPUT 1-8 SPECIFICATIONS
Description Value
Output Type Non-latching relay
Maximum Output Voltage 250 VAC or 30 VDC
Maximum Output Current from Normally-open Contact 3A
Maximum Output Current from Normally-closed Contact 3A
4.1.4.3 AUX 101 J3
Pin Description
Description Value
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4.1.4.4 AUX 101 J4
Pin Description
Description Value
4.1.4.5 AUX 101 J5

If the AUX 101 is connected to an AUX 102, this is connected to J6 on the AUX 102.
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There is no pin description for AUX 101 J5.
4.1.4.6 AUX 101 J10
Pin Description
J10-1 CAN H
J10-2 CAN L
J10-3 Current source 1
J10-7 Voltage source 1
J10-8 Voltage source 2
J10-9 Ground for current source or voltage source
4.1.4.6.1 AUX 101 Current Source Specifications
TABLE 37. AUX 101 CURRENT SOURCE SPECIFICATIONS
Description Value
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Maximum Output Current 20 mA
4.1.4.6.2 AUX 101 Voltage Source Specifications
TABLE 38. AUX 101 VOLTAGE SOURCE SPECIFICATIONS
Description Value
Output Voltage 5 VDC
Maximum Output Current 20 mA
4.1.4.7 AUX 101 J11
Pin Description
J11-1 AUX 101 input 1, reference input
J11-2 AUX 101 input 1, switch input
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4.1.4.7.1 AUX 101 Input 1-2 Specifications
TABLE 40. AUX 101 INPUT 1-2 SPECIFICATIONS
Description Value
Input Type Discrete or analog
Maximum Input Voltage 24 VDC
Differential Voltage Range -5~5 VDC
Description Value
Differential Voltage Range 0~5 VDC
Description Value
Differential Voltage Range 0~38 VDC
4.1.4.8 AUX 101 J14
Pin Description
J14-1 Input power B+
J14-2 Input power B-
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4.1.4.8.1 AUX 101 and AUX 102 Power Specifications
TABLE 44. AUX 101 AND AUX 102 POWER SPECIFICATIONS
Description Value
Input Voltage 5-40 VDC
Operating Voltage 12 VDC or 24 VDC
Current Consumption 900 mA (12 VDC)
450 mA (24 VDC)
4.2 AUX 102 Board
FIGURE 10. AUX 102 BOARD
4.2.1 AUX 102 LEDs

TABLE 45. AUX 102 LEDS
LED (Color) Description

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4.2.2 AUX 102 Connectors

TABLE 46. AUX 102 CONNECTORS
Connector Description
J1 AUX 102 outputs 1-8, normally-open contacts
J2 AUX 102 outputs 1-8, common contacts
J3 AUX 102 outputs 1-8, normally-closed contacts
J4 AUX 102 inputs 9-12
J5 Chassis ground
J6 Connection to AUX 101
4.2.2.1 AUX 102 J1
Pin Description
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4.2.2.2 AUX 102 J2
Pin Description
4.2.2.3 AUX 102 J3
Pin Description
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4.2.2.4 AUX 102 J4
Pin Description
4.2.2.5 AUX 102 J5

J5 is connected to a good earth ground.
4.2.2.6 AUX 102 J6

This is connected to J5 on the AUX 101.

There is no pin description for AUX 102 J6.
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4.3 How to Install the AUX 101/102 Hardware

WARNING: Incorrect installation, service, or replacement of parts can result in severe
personal injury or death and/or equipments 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.
WARNING: If present, always disconnect a battery charger from its AC source before
disconnecting the battery cables. Otherwise, disconnecting the cables can
result in voltage spikes high enough to damage the DC control circuits of the
generator set.
WARNING: 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 generator set 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 can ignite battery gases. Ventilate the area
before working on batteries. Wear safety glasses and do not smoke. Always
stop the generator set before disconnecting the battery. Always disconnect
the negative (–) cable first and reconnect it last.
NOTE: Mounting hardware for the AUX 101 and AUX 102 are not included. These
instructions include suggested hardware sizes.
1. Make sure the generator set is shut down and disabled.
a. The controller is in the Off mode.
b. The generator set Run/Off/Auto switch is in the Off position, and the generator set is
cool to the touch.
c. The emergency stop button has been pressed for at least thirty seconds.
d. Any power supplies (for example, heaters or pumps) are isolated. The battery charger
and starting battery should be isolated later.
e. The battery charger (if equipped) is turned off and disconnected.
f. The negative (-) cable from the battery is disconnected to prevent accidental starting.
g. A "Maintenance in Progress" sign is displayed, and the appropriate lockout/tagout
procedures are followed.
2. Select a suitable location, and mount the AUX 101 using M4 screws and associated
hardware.
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3. If the AUX 102 is included, use M4 screws and associated hardware to mount the AUX 102
near the AUX 101, and plug the AUX 102 J6 connector into the AUX 101 J5 connector.
Use a screw and lock washer to ground the AUX 102 J5 ring terminal.
4. Install any new sensors or switches that you plan to connect to the AUX 101 or AUX 102.
5. Select appropriate wire, and connect wiring from the controller TB1 connector to the
enclosed 5-pin connector. Plug the connector into the AUX 101 J1 connector.
6. Connect any system equipment to AUX 101 outputs and, if installed, AUX 102 outputs.
7. Connect any system equipment to AUX 101 inputs and, if installed, AUX 102 inputs.
8. Connect any system equipment to AUX 101 ground, voltage sources, and current sources.
9. Select the appropriate wire for power connections, and install wiring on the enclosed 2-pin
connector. Connect the wiring to the power source, and plug the connector into the AUX
101 J14 connector.
10. Reconnect the generator set.
a. Connect the negative (-) cable to the battery.
b. Reconnect the battery charger (if equipped).
c. Reconnect any other power supplies.
d. Unpress the emergency stop button, and reset the fault in the controller.
e. Place the Run/Off/Auto switch in the desired position.
f. Set the controller to the desired mode.
11. Verify that the AUX 101 LED DSL1 is green and that all devices are powered.
4.3.1 Wiring Diagrams Available

See Wiring Diagrams for wiring diagrams you can use in these procedures.
4.3.2 Guidelines for Mounting the AUX 101/102

The AUX 101 and AUX 102 are suitable for mounting on a non-engine panel inside an
enclosure. They should not be mounted directly on the engine.
To prevent the AUX 101 and AUX 102 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 AUX 101 and AUX 102 in a manner that would expose them to direct sunlight,
rain, or snow.
Choose a clean, vibration-free mounting surface. Avoid locations that are hot, damp, or dusty or
that are close to sources of electromagnetic interference (EMI).
4.3.2.1 AUX 101 and AUX 102 Environmental Specifications

TABLE 51. AUX 101 AND AUX 102 ENVIRONMENTAL SPECIFICATIONS
Description Value
Storage Temperature -40~85 C (-40~185 F)
Operating Temperature -40~60 C (-40~140 F)
Maximum Humidity 95%, non-condensing
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4.3.2.2 AUX 101 and AUX 102 Footprint
FIGURE 16. AUX 101 AND AUX 102 FOOTPRINT
NOTE: The outside dimensions do not include necessary clearance for wire
connections.
4.3.3 Pin Connections for AUX 101 Inputs 1-8

TABLE 52. PIN CONNECTIONS FOR AUX 101 INPUTS 1-8
Input Pins
1 J11-1, J11-2
2 J11-3, J11-4
3 J11-5, J11-6
4 J11-7, J11-8
5 J11-9, J11-10
6 J11-11, J11-12
7 J11-13, J11-14
8 J11-15, J11-16
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4.3.4 Pin Connections for AUX 102 Inputs 9-12

TABLE 53. PIN CONNECTIONS FOR AUX 102 INPUTS 9-12
Input Pins
9 J4-1, J4-2
10 J4-3, J4-4
11 J4-5, J4-6
12 J4-7, J4-8
4.3.5 Pin Connections for AUX 101 Outputs 1-8

TABLE 54. PIN CONNECTIONS FOR AUX 101 OUTPUTS 1-8
Output Pins
1 J2-1, J2-2, J2-3
2 J2-4, J2-5, J2-6
3 J2-7, J2-8, J2-9
4 J2-10, J2-11, J2-12
5 J3-1, J3-2, J3-3
6 J3-4, J3-5, J3-6
7 J4-1, J4-2, J4-3
8 J4-4, J4-5, J4-6
4.3.6 Pin Connections for AUX 102 Outputs 9-16

TABLE 55. PIN CONNECTIONS FOR AUX 102 OUTPUTS 9-16
Output Pins
9 J1-1, J2-1, J3-1
10 J1-2, J2-2, J3-2
11 J1-3, J2-3, J3-3
12 J1-4, J2-4, J3-4
13 J1-5, J2-5, J3-5
14 J1-6, J2-6, J3-6
15 J1-7, J2-7, J3-7
16 J1-8, J2-8, J3-8
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4.3.7 Example of a Connection
FIGURE 17. EXAMPLE OF A CONNECTION
NOTE: Input pin is grounded.
4.3.8 RTDs - About Four-wire Connections

When measuring the resistance of a RTD (resistance temperature detector or resistive thermal
device) located a significant distance away, the resistance in the wire can reduce the accuracy
of the measurement. In this case, a four-wire connection can provide a more accurate
measurement.
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FIGURE 18. FOUR-WIRE CONNECTION

In a four-wire connection, one set of wires provides a fixed current to the component, and a
second set of wires measures the voltage drop across the component. The resistance is
calculated by dividing the voltage drop by the fixed current.
While there is resistance in the wires that measure the voltage drop, the voltmeter produces
much less current than the current source, so the voltage drop due to resistance in the voltmeter
wires is significantly smaller.
4.3.8.1 How to Convert a Four-wire Connection Into a Two-wire

Connection
If you want to make a two-wire connection to a device that provides a four-wire connection,
connect a jumper between each pair of pins.
FIGURE 19. HOW TO CONVERT A FOUR-WIRE CONNECTION INTO A TWO-WIRE CONNECTION

In this type of connection, the voltmeter measures the voltage drop across the component and
the voltage drop due to resistance in the wire. As a result, the longer the wires, the more
inaccurate the measurement.
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If you want to make a three-wire connection, connect a jumper between one pair of pins. The
accuracy of a three-wire connection is better than that of a two-wire connection but worse than
that of a four-wire connection.
4.3.9 Example of a Voltage Bias Connection with One Power

Supply
FIGURE 20. EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH ONE POWER SUPPLY
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4.3.10 Example of a Voltage Bias Connection with Two Power

Supplies
FIGURE 21. EXAMPLE OF A VOLTAGE BIAS CONNECTION WITH TWO POWER SUPPLIES
4.3.11 Example of a Speed Bias Connection
FIGURE 22. EXAMPLE OF A SPEED BIAS CONNECTION
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5 Configuration of the AUX 101 and AUX
102 with Various Controllers
5.1 Tools to Configure a PCC 1301 or PowerCommand
1.x AUX 101/102
You must use one of these tools to configure the AUX 101 and AUX 102 settings in the
controller.
· Operator panel
· InPower service tool
NOTE: For some settings, InPower has more options than the operator panel. If you
use InPower to select an option that is not available in the operator panel, the
operator panel displays "N/A".
5.1.1 About the I/O Module Menus

Use the I/O Module menus to configure the inputs and outputs on the AUX 101 and, if installed,
AUX 102.
The I/O Module menu consist of three submenus.
· Inputs: Select the function of each input, and configure any inputs that are active-high
switches or active-low switches. Once an input is configured, you can use this submenu to
look at the current value of the input.
· Outputs: Configure each output.
· Senders: Configure any inputs that are senders.
The Senders submenu does not appear unless one or more inputs are senders.
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5. Configuration of the AUX 101 and AUX 102 with Various Controllers 11-2010
5.1.1.1 How to Find the I/O Module Menu in the PCC 1301 Operator Panel
FIGURE 23. HOW TO FIND THE I/O MODULE MENU IN THE PCC 1301 OPERATOR PANEL
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11-2010 5. Configuration of the AUX 101 and AUX 102 with Various Controllers
NOTE: If the password is not entered or is entered incorrectly, you can view the
menus, but the CONFIG and ADJUST buttons are blacked out. You will not be
able to change any values.
5.1.1.2 How to Configure a Switch on a PCC 1301, PCC 1302, or

PowerCommand 1.x
1. Go to the I/O Module menu.
2. Press the appropriate button to go to the Inputs submenu.
3. Press the selection buttons to find the input that will be a switch.
4. Press the CONFIG button to configure the input. The operator panel should display a list of
available functions for the input.
5. Press the appropriate button to set the function of the input to "Switch". The operator panel
should display the current settings of the switch.
6. Press the ADJUST button to configure the switch.
7. Enter a brief description of the event (up to 32 characters) and the event type (Event,
Warning, or Shutdown).
8. Press the SAVE button to save your changes.
9. Select the event logic (Active Low or Active High).
5.1.1.3 How to Configure an Active-low Switch on a PCC 1301, PCC 1302,

or PowerCommand 1.1
3. Press the selection buttons to find the input that will be an active-low switch.
4. Press the CONFIG button to configure the input. The operator panel should display the
current settings of the active-low switch.
5. Press the ADJUST button to configure the active-low switch.
6. Enter a brief description of the event (up to 32 characters) and the event type (Event,
Warning, or Shutdown).
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5.1.1.4 How to Configure a Voltage Bias on a PCC 1301, PCC 1302, or

PowerCommand 1.x
3. Press the selection buttons to find the input that will be a voltage bias.
available functions for the input. If "Voltage Bias" is not available, select an input that can
be a voltage bias.
5. Press the appropriate button to set the function of the input to "Voltage Bias". The operator
panel should display the current settings of the voltage bias.
6. Press the ADJUST button to configure the voltage bias.
7. Press the (+) and (-) buttons to set the voltage bias scale. The scale sets the range of the
voltage bias. For example, if the scale is 3 V, the voltage bias is +/- 3 V.
5.1.1.5 How to Configure a Speed Bias on a PCC 1301, PCC 1302, or

PowerCommand 1.x
3. Press the selection buttons to find the input that will be a speed bias.
available functions for the input. If "Speed Bias" is not available, select an input that can be
a speed bias.
5. Press the appropriate button to set the function of the input to "Speed Bias". The operator
panel should display the current settings of the speed bias.
6. Press the ADJUST button to configure the speed bias.
7. Press the (+) and (-) buttons to set the speed bias scale. The scale sets the range of the
speed bias. For example, if the scale is 120 rpm, the voltage bias is +/- 120 rpm.
5.1.1.6 How to Configure a Sender on a PCC 1301, PCC 1302, or

PowerCommand 1.x
3. Press the selection buttons to find the input that will be a sender.
available functions for the input. If "Sender" is not available, select an input that can be a
sender.
5. Press the appropriate button to set the function of the input to "Sender". The operator panel
should display the available types of senders.
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6. Press the appropriate button to select the type of sender this input will be. The operator
panel should display the current event type of the sender.
7. Press the ADJUST button to configure the event type of the sender.
8. Press the (+) and (-) buttons to set the event type, which varies by type of sender.
10. Return to the I/O Module menu.
11. Press the appropriate button to go to the Senders submenu.
12. Press the selection buttons to find the type of sender this input will be. The operator panel
should display the current settings of the sender.
13. Press the ADJUST button to configure the sender.
14. Enter the appropriate settings for the sender. The settings vary by type of sender.
5.1.1.6.1 Typical Electrical Characteristics of Various Sensors

This table provides information for reference only. It should not be used to configure any
devices that will be connected to the sensors.
CAUTION: Use the documentation provided with a sensor to configure any device that will be
connected to the sensor. Failure to do so may result in equipment damage.
TABLE 56. TYPICAL ELECTRICAL CHARACTERISTICS OF VARIOUS SENSORS
Type of Sensor Typical Characteristics

Oil temperature 600-2200 ohms
Exhaust temperature 80-400 ohms
Ambient air temperature 600-2200 ohms
Fuel level 600-2500 ohms
Alternator temperature PT 100 RTD
100 ohms @ 0 C (32 F), 0.385 ohms/C (0.214 ohms/F)
5.1.1.7 How to Configure an Output on a PCC 1301, PCC 1302, or

PowerCommand 1.x
2. Press the appropriate button to go to the Outputs submenu.
3. Press the selection buttons to find the output you want to configure.
4. Press the ADJUST button to configure the output.
5. Enter the fault code that should be associated with the output.
5.1.2 Using InPower to Configure the AUX 101 and AUX 102
You can use InPower to configure the AUX 101 and AUX 102, but there are no procedures for
this in this manual.
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5.2 Tools to Configure a PCC 2100 AUX 101/102

You must use the InPower service tool to configure the AUX 101 and AUX 102 settings in the
controller.
5.2.1 How to Disable or Enable an AUX 101 on the PCC 2100

In InPower, go to the AUX 101 Setup folder, and change the value of "AUX 101('s) Enable".
5.2.2 How to Configure a Switch on the PCC 2100

1. In InPower, go to the "AUX 101 Device #1 Inputs" folder.
2. Set the "Device #1 Input Sensor Type" parameter for the input that will be a switch.
3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a switch.
4. Save your changes in InPower.
5.2.3 How to Configure a Voltage Bias on a PCC 2100

2. Set the "Device #1 Input Sensor Type" parameter to "Bias Sensor" for the input that will be
a voltage bias.
3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a voltage
bias.
4. Go to the "AUX 101 Setup" folder.
5. Set the "Voltage Bias Scale" parameter according to the voltage bias connection.
· For a voltage bias connected to two power supplies (for example, +5 V and -5 V), set
this parameter to the maximum increase in voltage the voltage bias can create.
· For a voltage bias connected to one power supply (for example, +5 V and ground),
set this parameter to two times the maximum increase in voltage the voltage bias can
create.
6. Set the "Voltage Bias Enable" parameter to "Enable".
7. For a voltage bias connected to one power supply, set the "Voltage Adjust" parameter to
the result of the following calculation.
a. Start with the maximum increase in voltage the voltage bias can create.
b. Divide it by the generator set nominal voltage.
c. Multiply the result by -100.
For a voltage bias connected to two power supplies, skip this step.
5.2.4 How to Configure a Speed Bias on a PCC 2100

2. Set the "Device #1 Input Sensor Type" parameter to "Bias Sensor" for the input that will be
a speed bias.
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3. Set the "Device #1 Input Enable" parameter to "Enable" for the input that will be a speed
bias.
4. Go to the "AUX 101 Setup" folder.
5. Set the "Speed Bias Scale" parameter to the maximum increase in RPM the speed bias
can create.
6. Set the "Speed Bias Enable" parameter to "Enable".
5.2.5 How to Configure an Output on a PCC 2100

1. In InPower, go to the "AUX 101 Device Outputs" folder for the AUX 101 to which the output
belongs.
2. Set the "Device Output Relay Fault Code Mapping" parameter to the fault code that should
be associated with the output.
3. Set the "Device Output Relay Enable" parameter to "Enable" for the output you want to
configure.
5.3 Tools to Configure a PowerCommand 2.x or 3.x

AUX 101/102
You must use one of these tools to configure the AUX 101 and AUX 102 settings in the
controller.
· Operator panel
· InPower service tool
· Modbus connection
5.3.1 How to Find the AUX 101 Setup Screens in the Operator
Panel
The AUX 101 Setup screens are available on the main menu.
1. Go to the Home screen.
2. Change the selection in the graphical display until "AUX 101 Setup" is selected. Use the
selection buttons to change page, if necessary.
3. Press OK.
5.3.2 How to Configure a Switch on the PowerCommand 2.x or

3.x
1. Set "AUX 101 Analog Input Sensor Type" to "Switch Input - Active Closed" or "Switch Input
- Active Open" for the input that will be a switch.
2. Enter a brief description of the event in "AUX 101 Input Fault Text" for the input that will be
a switch.
3. Set "AUX 101 Input Function Pointer" to "Default" for the input that will be a switch.
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4. Save your changes.
5.3.3 How to Configure an Additional Function for AUX 101

Inputs on the PowerCommand 2.x or 3.x
1. Set "AUX 101 Analog Input Sensor Type" to "Switch Input - Active Closed" or "Switch Input
- Active Open" for the input that will be a switch.
2. Set "AUX 101 Input Function Pointer" to the desired function for the input that will be a
switch. If the selection is rejected, the desired function is already used by another input.
3. Set the appropriate settings for the desired function. The related settings vary by function.
5.3.3.1 Example: Configure AUX 101 Input #3 as a Low Fuel in Day Tank
Switch on the PowerCommand 2.x or 3.x
In this example, the Low Fuel in Day Tank Switch is active-closed, and the switch must be
active for five seconds before the controller generates a fault.
1. Set "AUX101 0 Analog Input 3 Sensor Type" to "Switch Input - Active Closed".
2. Set "AUX101 0 Input 3 Function Pointer" to "Low Fuel in Day Tank Switch".
3. Set "Low Fuel in Day Tank Time" to 5 seconds.
5.3.4 How to Configure an Analog Input on the PowerCommand

2.x or 3.x
1. Set "AUX 101 Analog Input Sensor Type" to "Analog Input" for the input that will be an
analog input.
2. Set "AUX 101 Analog Input Function Pointer" to the desired function.
3. Set the appropriate settings for the desired function. The related settings vary by function.
5.3.4.1 Example: Configure AUX 101 Input #4 as an Alternator

Temperature Sensor on the PowerCommand 2.x or 3.x
In this example, the alternator temperature sensor must be at least 300 degrees F for five
seconds before the controller generates a fault. The out-of-range check is active, and the
sensor must be outside 0.2-4.8 VDC for two seconds before the controller generates a fault.
1. Set "AUX101 0 Analog Input 4 Sensor Type" to "Analog Input".
2. Set "AUX101 0 Analog Input 4 Function Pointer" to "Alternator Temperature 1".
3. Set "High Alternator Temperature 1 Threshold (Aux101)" to 300 degrees F.
4. Set "High Alternator Temperature 1 Time (Aux101)" to 5 seconds.
5. Set "Aux101 Alternator Temperature OOR High Limit" to 4.8 VDC.
6. Set "Aux101 Alternator Temperature OOR Low Limit" to 0.2 VDC.
7. Set "Aux101 Alternator Temperature OOR Time" to 2 seconds.
46 A030K737 (Issue 2)
8. Set "Aux101 Alternator Temperature OOR Check Enable" to "Enable".

5.3.4.2 Typical Electrical Characteristics of Various Sensors

This table provides information for reference only. It should not be used to configure any
devices that will be connected to the sensors.
CAUTION: Use the documentation provided with a sensor to configure any device that will be
connected to the sensor. Failure to do so may result in equipment damage.
TABLE 57. TYPICAL ELECTRICAL CHARACTERISTICS OF VARIOUS SENSORS
Type of Sensor Typical Characteristics

Oil temperature 600-2200 ohms
Exhaust temperature 80-400 ohms
Ambient air temperature 600-2200 ohms
Fuel level 600-2500 ohms
Alternator temperature PT 100 RTD
100 ohms @ 0 C (32 F), 0.385 ohms/C (0.214 ohms/F)
5.3.5 How to Configure an Output on the PowerCommand 2.x or

3.x
1. Set "AUX 101 Output Function Pointer" to the desired function for the output.
2. If the desired function is "Default", set "Aux 101 Output Fault/Event" to the fault code that
should be associated with the output.
5.3.5.1 Example: Configure AUX 101 Output #1 as a Low Coolant Level #2

Output on the PowerCommand 2.x or 3.x
Low Coolant Level #2 is event/fault code 2977.
1. Set "Aux101 0 Output 1 Function Pointer" to "Default".
2. Set "Aux101 0 Output 1 Fault/Event" to 2977.
A030K737 (Issue 2) 47
48 A030K737 (Issue 2)
6 Manufacturing Facilities
NORTH AMERICA EMEA, CIS ASIA PACIFIC
Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited
1400 73rd Ave. NE Columbus Avenue 10 Toh Guan Road #07-01
Minneapolis, MN 55432 USA Manston Park TT International Tradepark
Manston, Ramsgate Singapore 608838
Kent CT12 5BF
United Kingdom
Phone 1 763 574 5000 Phone 44 1843 255000 Phone 65 6417 2388
Toll Free 1 800 888 6626 Fax 44 1843 255902 Fax 65 6417 2399
Fax 1 763 574 5298
BRAZIL CHINA INDIA

Rua Jati, 310, Cumbica Cummins Power Generation 35A/1/2, Erandawana
Guarulhos, SP 07180-900 2 Rongchang East Street, Pune 411 038
Brazil Beijing Economic – Technological India
Development Area
Beijing 100176, P.R.China
Phone 55 11 2186 4195 Phone 86 10 5902 3000 Phone 91 020 6602 7525
Fax 55 11 2186 4729 Fax 86 10 5902 3199 Fax 91 020 6602 8090
LATIN AMERICA MEXICO

3350 Southwest 148th Ave. Eje 122 No. 200 Zona Industrial
Suite 205 San Luis Potosi, S.L.P. 78395
Miramar, FL 33027 Mexico
USA
Phone 1 954 431 551 Phone 52 444 870 6700
Fax 1 954 433 5797 Fax 52 444 824 0082
A030K737 (Issue 2) 49
6. Manufacturing Facilities 11-2010
50 A030K737 (Issue 2)
Appendix A. Wiring Diagrams
Table of Contents
Figure 24. AUX 101, 0630-3142, Sheet 1 of 2 ............................................................................................. 53
Figure 25. AUX 102, 0630-3142, Sheet 2 of 2 ............................................................................................. 54
Figure 26. PCC 1301 and AUX 101/102, 0630-2926, Sheet 1 of 1 ............................................................. 55
Figure 27. PCC 2100 and AUX 101/102, 0612-6764, Sheet 1 of 1 ............................................................. 56
Figure 28. PCC 1302/PowerCommand 1.x and AUX 101/102, 0630-3440, Sheet 1 of 2 ......................... 57
Figure 29. PowerCommand 2.x/3.x and AUX 101/102, 0630-3440, Sheet 2 of 2 ..................................... 58
A030K737 (Issue 2) 51
Appendix A. Wiring Diagrams 11-2010
52 A030K737 (Issue 2)
11-2010 Appendix A. Wiring Diagrams
FIGURE 24. AUX 101, 0630-3142, SHEET 1 OF 2
A030K737 (Issue 2) 53
FIGURE 25. AUX 102, 0630-3142, SHEET 2 OF 2
54 A030K737 (Issue 2)
FIGURE 26. PCC 1301 AND AUX 101/102, 0630-2926, SHEET 1 OF 1
A030K737 (Issue 2) 55
FIGURE 27. PCC 2100 AND AUX 101/102, 0612-6764, SHEET 1 OF 1
56 A030K737 (Issue 2)
FIGURE 28. PCC 1302/POWERCOMMAND 1.X AND AUX 101/102, 0630-3440, SHEET 1 OF 2
A030K737 (Issue 2) 57
FIGURE 29. POWERCOMMAND 2.X/3.X AND AUX 101/102, 0630-3440, SHEET 2 OF 2
58 A030K737 (Issue 2)
Copyright © 2010 Cummins Power Generation, Inc. All rights reserved.
Cummins, the "C" logo, and "Our energy working for you." are trademarks of
Cummins Inc.

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Owner Manual

English - Original Instructions11-2010 A030K737 (Issue 2)

APPENDIX A. WIRING DIAGRAMS ................................................................................................. 51

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FUEL AND FUMES ARE FLAMMABLE

EXHAUST GASES ARE DEADLY

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)

GENERAL SAFETY PRECAUTIONS

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2.2 About the AUX 101

2.2.1 Number of Additional Inputs and Outputs on the AUX 101

2.2.2 About AUX 101 Inputs

2.2.3 About AUX 101 Outputs

2.3 About the AUX 102

NOTE: The AUX 102 requires the AUX 101.

2.3.1 Number of Additional Inputs and Outputs on the AUX 102

Number of Additional Inputs 4

2.3.2 About AUX 102 Inputs

2.3.3 About AUX 102 Outputs

2.4 About the Numbering of AUX 102 Inputs and

3.1 Characteristics of the AUX 101 and AUX 102 with

3.1.2 Required Part Numbers for Operator Panel Software to

Software Part Number

3.1.2.2 Configuration Limitations in Operator Panel Software Version

3.1.2.3 How to Upgrade Software on the AUX 101

Input Possible Functions

Input Fault Code

Output Default Function

3.1.4.1 About AUX 101 Output 4

Input Possible Functions

Input Fault Code

Output Default Function

3.2 Characteristics of the AUX 101 and AUX 102 with

3.2.2 Possible Functions of AUX 101 Inputs for PCC 2100

Input Possible Functions

3.2.2.1 Default Functions of AUX 101 Inputs for PCC 2100

Output Default Function

3.2.3.1 About AUX 101 Output 4

3.2.4 Possible Functions of AUX 102 Inputs for PCC 2100

Input Possible Functions

3.2.4.1 Default Functions of AUX 102 Inputs for PCC 2100

Output Default Function

3.3 Characteristics of the AUX 101 and AUX 102 with

Component Part Number

3.3.3 Possible Functions of AUX 101 Inputs for PowerCommand

Input Possible Functions

3.3.3.2 Additional Functions of Configurable Inputs on the

TABLE 19. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 2.X

Function Related Settings

3.3.3.3 Additional Functions of Configurable Inputs on the

TABLE 20. ADDITIONAL FUNCTIONS OF CONFIGURABLE INPUTS ON THE POWERCOMMAND 3.X

Function Related Settings

3.3.3.4 Additional Functions of Configurable Analog Inputs on the

TABLE 21. ADDITIONAL FUNCTIONS OF CONFIGURABLE ANALOG INPUTS ON THE

Function Related Settings

Oil Temperature High Oil Temperature Threshold (Aux101), High Oil