Instruction Sheet
C698 3-2006
Installation and Setup Instructions for I/O Module Kit 5411320
This instruction sheet describes the installation
and configuration of an I/O Module on gensets with
a PCC2100 control. This Instruction Sheet pro-
vides information on how to install the I/O Module
kit and provides control configuration information
for gensets that already have the I/O Module
installed.
INTRODUCTION
The PowerCommand I/O Module is an option that
can be used on generator sets with a PCC2100
control. The I/O Module can be used in a 12 or 24
VDC system.
The PCC2100 control, starting with software ver-
sion 2.500, supports up to two Base I/O Modules
and two Expansion I/O Modules.
If your installation includes both the Base I/O Mod-
ule (AUX101) and the optional Expansion I/O Mod-
ule (AUX102), sixteen relay outputs and two dis-
crete analog inputs are available for auxiliary con-
trol and monitoring of the power system.
Relay outputs can be used for controlling equip-
ment such as motors, louvers, fans, and pumps.
The relays can be configured individually by using
InPower software.
PowerCommand is a registered trademark of Cummins Inc.
Base I/O Module (AUX101)
The PowerCommandR AUX101 I/O Module (see
Figure 1) includes the following.
S Eight discrete Form-C relay output sets
used to control system equipment. Each
relay includes a status LED (DS3 thru
DS10).
S Inputs 1 and 2 can be configured for voltage
and speed bias as a means to match the
voltage and frequency of the generators
prior to the control being set up for active
droop paralleling operation.
S Two 5 VDC voltage sources to be used with
active senders.
S Two network status LEDs.
DS1 (green) indicates the AUX101 is
connected to the network and is operat-
ing normally.
DS2 (red) indicates the AUX101 has
lost it connection or is not connected to
the network.
S One device number indicator (U16) that is
used to uniquely identify an I/O Module
when more than one AUX101 is included on
the same network.
Page 1 of 15
Since the AUX101 does not require any special TABLE 1. AUX101 CONNECTORS
configuration, it can be used immediately. It in-
cludes the following default settings: Connector Pins Description

S All inputs are disabled except for the two J1 5 Connection to 1301 control
analog inputs J2 12 Dry contact outputs 1 4
S Outputs are mapped as follows: J3 6 Dry contact outputs 5 6
1 Low Oil Pressure J4 6 Dry contact outputs 7 8
2 High Engine Temperature J5 20 AUX102 connection
3 Not Defined
J6 6 Not used
4 Battery (Low, Weak, or High)
5 Overspeed J7 6 Not used
6 Fail to Start J10 12 GND, 5V sources, current
7 Not In Auto sources
8 Run J11 16 Analog/Digital inputs 1 8
The I/O Module includes the connectors listed in J14 2 Connection to power
Table 1. source

J11 J10

DEVICE
NUMBER
INDICATOR

S1
J14 (DEV#)

J1

J5

DS1

DS2

J2 J3 J4

FIGURE 1. BASE I/O MODULE (AUX101)

C698
Page 2 of 15
EXPANSION I/O MODULE (AUX102) A ribbon cable is used to connect the Expansion
I/O Module to the Base I/O Module. The AUX102
includes the following default settings:
The PowerCommandR AUX102 is an Expansion
I/O Module (see Figure 2). If your installation is to S All inputs are disabled
include an AUX102, your must purchase kit
5410772. S Outputs are mapped as follows:
9 Pre-Low Oil Pressure
10 Pre-High Engine Temperature
The AUX102 Expansion I/O Module includes the
following. 11 Not Defined
12 Not Defined
13 Low Engine Temperature
S Eight Form-C relay output sets used to con- 14 Not Defined
trol system equipment. Each relay includes 15 Not Defined
a status LED (DS1 thru DS8). 16 Not Defined

J4 (CUSTOMER INPUTS) MOUNTING SCREW AND

LOCK WASHER (NOT
INCLUDED IN THIS KIT)

J5 RING
EIGHT FORM-C TERMINAL
RELAY CONTACTS

J6
J3

J2

J1

FIGURE 2. EXPANSION I/O MODULE (AUX102)

C698
Page 3 of 15
 INSTALLATION
The following parts are included in the I/O Module
kit.
Description Qty
I/O Module 1 CAUTION If present, always disconnect a
Connector (2 Pin) 1 battery charger from its AC source before dis-
Connector (5 Pin) 1 connecting the battery cables. Otherwise, dis-
The following part is not included in the I/O Module
kit but may be needed for your installation.
Description Part Number
Expansion I/O Module 5410772
Read these instructions completely and become
familiar with safety warnings, cautions, and proce-
dures before starting the installation.
Mounting Guidelines
The I/O Module is suitable for non-engine panel
mounting within an enclosure. As such, it should
not be directly mounted on the engine.
To prevent the I/O Module from being exposed to
conditions beyond its specifications, care should
be taken not to mount it close to the engine exhaust
pipes. Avoid mounting the Module(s) in a manner
that would expose them to direct sunlight or rain/
snow.
Choose a clean, vibration-free mounting surface.
Avoid locations that are hot, damp, or dusty or that
are close to EMI sources. The AUX101 and
AUX102 are designed for proper operation in
ambient temperatures from 40 to +60 Degrees C
(40 to 140 Degrees F), and for storage from 40
to +80 Degrees C (40 to 176 Degrees F). The
modules are designed to operate with humidity up
to 95%, non-condensing.
Physical Installation
WARNING Incorrect installation, service, or
replacement of parts can result in severe per-
sonal injury or death and/or equipment dam-
age. Only trained and experienced personnel
are to perform the following procedures.
C698
Page 4 of 15
WARNING AC voltages and currents present
an electrical shock hazard that can cause se-
vere personal injury or death. Incorrect instal-
lation, service, or parts replacement can result
in severe personal injury, death, and/or equip-
ment damage.
connecting the cables can result in voltage
spikes high enough to damage the DC control
circuits of the generator set.
WARNING Accidental starting of the genera-
tor 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 batteryWear
gogglesStop the genset and disconnect the
charger before disconnecting battery cables.
Arcing can ignite explosive hydrogen gas giv-
en off by batteries, causing severe personal in-
jury. 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, en-
gine fuel, and other explosive fumes are fully
dissipated. This is especially important if the
battery has been connected to a battery char-
ger.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death.
Arcing at battery terminals, light switch or oth-
er equipment, flame, pilot lights and sparks
can ignite battery gas. Do not smoke, or switch
trouble light ON or OFF near a battery. Dis-
charge static electricity from body before
touching batteries by first touching a
grounded metal surface.
Refer to the PCC2100 Control wiring diagram
(Figure 12) when connecting the I/O Module to the
PCC2100 control. This wiring diagram also in-
cludes information on wiring items (annunciator
and governor power module) not included in this
kit.
Refer to the I/O Module wiring diagram (Figure not include necessary clearance for wire con-
11) when connecting the I/O Module to other nections.
equipment.
3. If included in your installation, use M4 hard-
NOTE: Mounting hardware for the I/O Module is ware to mount the Expansion I/O Module (kit
not included in this kit. The instructions be- 5410772) near the Base I/O Module and plug
low include suggested hardware sizes. the Expansion I/O Modules J6 connector into
the Base I/O Modules J5 connector. Be sure
1. Make sure the generator set is shut down and to use a screw and lock washer to ground the
disabled: J5 ring terminal.
4. Select appropriate wire and connect wiring
a. The PCC2100 is in the Off mode. from the PCC2100 baseboard TB1 connector
b. The generator set Run/Off/Auto switch is to the enclosed 5-pin connector (see Figure
in the Off position and the generator is 12). Plug the connector into the J1 connector
cool (to the touch). on the AUX101.

c. The battery charger (if equipped) is
turned off and disconnected.
d. The negative () cable from the battery is
disconnected to prevent accidental start-
ing.
2. Select a suitable location and mount the I/O
Module using M4 hardware. Figure 3 shows
the Module dimensions (including the Expan-
sion I/O Module). The outside dimensions do
5. Connect any system equipment to the dry
contact output connectors on the AUX101 (J2,
J3, and J4) and, if installed, the AUX102 (J1,
J2, and J3).
6. Make connections for any analog/discrete in-
puts to the J11 connector on the AUX101 and,
if installed, the J4 connector on the AUX102.
7. If needed, connect GND, 5V sources, and cur-
rent sources to the J10 connector on the
AUX101.

0.51 (13) 5.31 (135) DIMENSIONS SHOWN

4.53 (115) 0.39 (10) IN INCHES (mm)
0.47 (12)

2.95 (75) 0.51 (13)

2.17 (55) 0.47 (12)

5.9
(150)
5.12 3.94
(130) BASE I/O MODULE (100)
EXPANSION
0.25 3.15 I/O MODULE
(6) (80)
B B

1.25 MIN (32)

2.5 MAX (63)
0.39 (10)

0.23 (5.9) 0.23 (5.9)

SECTION A-A SECTION B-B

FIGURE 3. I/O MODULE FOOTPRINT

C698
Page 5 of 15
 8. Select appropriate wire for power connections
and install wiring on the enclosed 2-pin con-
nector. Connect the wiring to the power
source (PCC2100 TB2-3 = B+ and TB2-4 =
B/GND see Figure 4) and plug the connec-
tor into the J14 connector on the AUX101.
9. Reconnect the genset as follows.
a. Connect the negative () cable to the bat-
tery.
b. Reconnect the battery charger (if used).
c. Place the Run/Off/Auto switch to the de-
sired position.
d. Set the PCC2100 to the desired mode.

TO PCCNET
DEVICES

DEFAULT SETTING
TB1-CUSTOMER FAULTS:
1 CUSTOMER FAULT 1
2 GROUND FAULT
3 LOW FUEL
4 RUPTURE BASIN FAULT
TB1-CUSTOMER RELAYS:
1 COMMON WARNING
2 COMMON SHUTDOWN
3 NOT IN AUTO
4 READY TO LOAD

FIGURE 4. PCC2100 CONTROL WIRING CONNECTIONS

C698
Page 6 of 15
10. Verify that the DS1 LED on the AUX101 is
green and that all devices are powered.
11. If your installation includes only one AUX101,
the device number displayed on the module is
0 (see Figure 1). If your installation includes
more than one AUX101,
a. Press and hold the S1 (DEV#) button for
a least five seconds, until a small dot ap-
pears next to the number displayed on
the device number indicator.
b. To change the device number, press and
release S1 until the desired number is
displayed. After five seconds of inactivity,
the new device number is set and the
small dot will go out.
c. After the device number has been
changed, cycle power from the I/O Mod-
ule by unplugging and replugging the J14
connector.
FIGURE 5. DISABLING THE I/O MODULE(S)
NOTE: The PCC2100 genset control current-
ly supports up to two AUX101s. If you
are using the speed/voltage bias in-
puts on an AUX101, the device num-
ber on that AUX101 must be set to 0.
12. Configure the I/O Module(s), as described in
the following pages.
I/O MODULE CONFIGURATION
The I/O Module can only be configured using the
PC service tool.
The AUX101 is a plug and play device. Once con-
nected to the PCCNet network, the PCC2100
should recognize it there. Up to two AUX101s can
be connected to a PCC2100. The user can disable
an AUX101 by changing the AUX101(s) Enable
setting to Disable (see Figure 5).
C698
Page 7 of 15
Although the AUX101 is designed for twelve net-
work inputs, only two of the inputs can currently be
used with the PCC2100 control. If more than one
AUX101 is connected to a PCC2100, speed and
voltage bias will only function on the device with
the device number set to 0.
Input 1 of the AUX101 is set up as a Voltage Bias
FIGURE 6. VOLTAGE AND SPEED BIAS ENABLE
C698
Page 8 of 15
input. It can only be used as a voltage bias input.
This feature must be enabled by changing the Volt-
age Bias Enable value to Enable.
Input 2 of the AUX101 is set up as a Speed Bias
input. It can only be used as a speed bias input.
This feature must be enabled by changing the
Speed Bias Enable value to Enable.
The Voltage Bias input has a range of 3V to +3V,
with 0V input corresponding to 0 voltage bias. The
Speed Bias has a range of 0V to 5V with 2.5V input
corresponding to 0 speed bias.
Both inputs have a Scale parameter which sets
up the minimum and maximum voltage or RPM
values that correspond to the AUX101 input volt-
ages. For example, if the Speed Bias scale is set to
200 RPMs, a 5V input into the AUX101 changes
the speed reference +200 RPMs. A 0V input into
the AUX101 changes the speed reference 200
RPMs. The Voltage Bias Scale acts the same way.

FIGURE 7. SPEED BIAS SCALE

C698
Page 9 of 15
All of the available relay outputs are supported with AUX102 expansion board is installed. Although
the PCC2100. Outputs 18 are available with the each output has a default fault assigned to it, they
AUX101 and outputs 916 are available if the can be changed using the menu shown below.

FIGURE 8. OUTPUT FAULT MENU FOR AUX101 DEVICE #1

C698
Page 10 of 15
Figure 9 shows the menu that can be used to
change the output values if a second AUX101 and
AUX102 are installed.

FIGURE 9. OUTPUT FAULT MENU FOR AUX101 DEVICE #2

C698
Page 11 of 15
The monitoring screen shown in Figure 10 display- board is installed and it shows the voltage and
s information about the AUX101 devices con- speed bias values based on the Scale value.
nected to the PCC2100. It shows if an expansion

FIGURE 10. AUX101 MONITORING SCREEN

C698
Page 12 of 15
 No. 630-3142 Sh 1 of 2
Rev. A Sys: HP
Modified 7/2005

FIGURE 11. I/O MODULE WIRING DIAGRAM

C698
Page 13 of 15
 No. 630-3142 Sh 2 of 2
Rev. A Sys: HP
Modified 7/2005

FIGURE 11. I/O MODULE WIRING DIAGRAM

C698
Page 14 of 15
 No. 612-6764 Sh 1 of 2
Rev. E Mod Sys: HP
Modified 1/2006

FIGURE 12. PCC2100 CONTROL WIRING

DIAGRAM
C698
Page 15 of 15