Installation and Setup Instructions for IO Module

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Page 1 of 45
Instruction Sheet
C693b 6-2006
Installation and Setup Instructions for I/O Module Kit 541–1291
This instruction sheet describes the installation and configuration of an I/O Module on gensets with a
PCC1301 control. This Instruction Sheet provides information on how to install the I/O Module kit and pro-
vides control configuration information for gensets that already have the I/O Module installed.
TABLE OF CONTENTS
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Base I/O Module (AUX101) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Expansion I/O Module (AUX102) 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Mounting Guidelines 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Physical Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
I/O Module Configuration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
AUX101/AUX102 Control Panel Configuration 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Adjusting Values/Parameters 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
I/O Module Submenus 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Network Inputs (Control Panels with Screen Software P/N 3266652) 14. . . . . . . . . 
Network Inputs (All Control Panels Except Those with Screen Software 
P/N 3266652) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Input 1 Configuration 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Input 2 Configuration 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Input 3 thru Input 6 Configuration 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Input 7 and Input 8 Configuration 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Input 9 thru Input 12 Configuration 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Network Input View Screens 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Relay Outputs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Outputs 1–3 and 5–16 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Output 4 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Senders 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Oil Temperature 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Exhaust Temperature 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Ambient Temperature 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Fuel Level 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Alternator RTD 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Intake Manifold Temperature 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
Wiring Diagrams 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 
PowerCommand is a registered trademark of Cummins Inc.
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C693b
INTRODUCTION
The PowerCommand I/O Module is an option that
can be used on generator sets with a PCC1301
control. The I/O Module can be used in a 12 or 24
VDC system.
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 twelve
discrete analog inputs are available for auxiliary
control and monitoring of the power system.
Eight customizable analog/discrete inputs can be
used for system fault expansion and/or genset me-
tering.
Relay outputs can be used for controlling equip-
ment such as motors, louvers, fans, and pumps.
The relays can be configured individually from the
genset control operator interface (PCC1301 con-
trol panel) or by using InPower software.
Base I/O Module (AUX101)
The PowerCommand� AUX101 I/O Module (see
Figure 1) includes the following.
� Eight discrete Form-C relay output sets
used to control system equipment. Each
relay includes a status LED (DS3 thru
DS10).
� Eight configurable inputs used to monitor
equipment status and faults. Equipment sta-
tus and fault conditions are annunciated.
Depending on the input (see Table 3), one of
the following seven pre-programmed func-
tions can be assigned.
– Oil temperature
– Exhaust temperature
– Fuel Level
– Ambient temperature
– Alternator RTD
– Speed bias
– Voltage bias
– Switch – Active Low
– Switch – Active High
� Two 5 VDC voltage sources to be used with
active senders.
� Four programmable current sources to be
used with resistive senders.
� 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.
� 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.
Since the AUX101 does not require any special
configuration, it can be used immediately. It in-
cludes the following default settings:
� All inputs are disabled.
� Outputs are mapped as follows:
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
The I/O Module includes the connectors listed in
Table 1.
TABLE 1. AUX101 CONNECTORS
Connector Pins Description
J1 5 Connection to 1301 control
J2 12 Dry contact outputs 1 – 4
J3 6 Dry contact outputs 5 – 6
J4 6 Dry contact outputs 7 – 8
J5 20 AUX102 connection
J6 6 Not used
J7 6 Not used
J10 12 GND, 5V sources, current
sources
J11 16 Analog/Digital inputs 1 – 8
J14 2 Connection to power
source
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J14
J1
J2 J3 J4
J5
DEVICE
NUMBER
INDICATOR
J10J11
DS1
DS2
S1
(DEV#)
FIGURE 1. BASE I/O MODULE (AUX101)
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C693b
EXPANSION I/O MODULE (AUX102)
The PowerCommand� AUX102 is an Expansion
I/O Module (see Figure 2). If your installation is to
include an AUX102, your must purchase kit
541–0772.
The AUX102 Expansion I/O Module includes the
following.
� Eight Form-C relay output sets used to con-
trol system equipment. Each relay includes
a status LED (DS1 thru DS8).
� Four isolated discrete inputs used to monitor
equipment status and faults. Equipment sta-tus and fault conditions are annunciated.
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:
� All inputs are disabled.
� Outputs are mapped as follows:
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
* Low Coolant Level and Low Fuel Level default
mapping is based on the PCC1301 Customer In-
puts being defined as Low Coolant Level or Low
Fuel Level. By default, the PCC1301 Customer
Inputs are defined in this manner.
EIGHT FORM-C
RELAY CONTACTS
J3
J2
J1
J6
J4 (CUSTOMER INPUTS)
J5 RING
TERMINAL
MOUNTING SCREW AND
LOCK WASHER (NOT
INCLUDED IN THIS KIT)
FIGURE 2. EXPANSION I/O MODULE (AUX102)
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INSTALLATION
The following parts are included in the I/O Module
kit.
Description Qty
I/O Module 1
Connector (2 Pin) 1
Connector (5 Pin) 1
The following parts are not included in the I/O Mod-
ule kit but may be needed for your installation.
Description Part Number
Expansion I/O Module 541–0772
Sensor Kit – Oil, Ambient, or
Intake Manifold Temperature
541–1300
Sensor Kit – Exhaust 
Temperature
541–1301
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
������� 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.
������� 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.
CAUTION If present, always disconnect a
battery charger from its AC source before dis-
connecting the battery cables. Otherwise, dis-
connecting the cables can result in voltage
spikes high enough to damage the DC control
circuits of the generator set.
������� 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 battery—Wear
goggles—Stop 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.
������� 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 1301 Control wiring diagram (Fig-
ure 13) when connecting the I/O Module to the
PCC1301 control. This wiring diagram also in-
cludes information on wiring items (annunciator
and governor power module) not included in this
kit.
Page 6 of 45
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Refer to the I/O Module wiring diagram (Figure
12) when connecting the I/O Module to other
equipment.
NOTE: Mounting hardware for the I/O Module is
not included in this kit. The instructions be-
low include suggested hardware sizes.
1. Make sure the generator set is shut down and
disabled:
a. The PCC1301 is in the Off mode.
b. The generator set Run/Off/Auto switch is
in the Off position and the generator is
cool (to the touch).
c. The battery charger (if equipped) is
turned off and disconnected.
d. The negative (–) cable from the battery is
disconnected to prevent accidental 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
not include necessary clearance for wire con-
nections.
3. If included in your installation, use M4 hard-
ware to mount the Expansion I/O Module (kit
541–0772) near the Base I/O Module and plug
the Expansion I/O Module’s J6 connector into
the Base I/O Module’s J5 connector. Be sure
to use a screw and lock washer to ground the
J5 ring terminal.
4. If your installation requires an oil temperature,
ambient temperature, and/or intake manifold
sensor, install kit 541–1300. Refer to Figure
12 for wiring information.
5. If your installation requires an exhaust tem-
perature sensor, install kit 541–1301. Refer to
Figure 12 for wiring information.
6. Select appropriate wire and connect wiring
from the PCC1301 baseboard TB1 connector
to the enclosed 5-pin connector (see Figure
13). Plug the connector into the J1 connector
on the AUX101.
7. 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).
B
DIMENSIONS SHOWN
IN INCHES (mm)
0.51 (13)
0.47 (12)
5.31 (135)
4.53 (115)
5.9
(150)
5.12
(130)
0.23 (5.9)
0.51 (13)2.95 (75)
2.17 (55)
3.94
(100)
3.15
(80)
0.23 (5.9)
B
SECTION B-B
0.47 (12)
SECTION A-A
0.25
(6)
1.25 MIN (32)
2.5 MAX (63)
BASE I/O MODULE
EXPANSION
I/O MODULE
0.39 (10)
0.39 (10)
FIGURE 3. I/O MODULE FOOTPRINT
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8. Make connections for any analog/discrete in-
puts to the J11 connector on the AUX101 and,
if installed, the J4 connector on the AUX102.
9. If needed, connect GND, 5V sources, and cur-
rent sources to the J10 connector on the
AUX101.
10. Select appropriate wire for power connections
and install wiring on the enclosed 2-pin con-
nector. Connect the wiring to the power
source (PCC1301 TB1-1 = B+ and TB1-4 =
B–) and plug the connector into the J14 con-
nector on the AUX101.
11. 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 PCC1301 to the desired mode.
12. Verify that the DS1 LED on the AUX101 is
green and that all devices are powered.
13. 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 andthe
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.
NOTE: The PCC1301 genset control current-
ly supports only one AUX101. Make
sure the device number is set to “0.”
14. Configure the I/O Module(s), as described in
the following pages.
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I/O MODULE CONFIGURATION
The I/O Module can be configured using the me-
nus available with the PCC1301 control panel or
the PC service tool.
There are some constraints associated with con-
figuration using the control panel. These const-
raints are dependant upon the version of control
panel being used. Newer versions of the control
panel allow for complete configuration of both the
AUX101 and the AUX102 while older version have
limited configuration capabilities.
� If your control panel version is SW P/N
3266796, then your control panel is capable
of configuring both the AUX101 and the
AUX102.
� If your control panel version is SW P/N
3266652, then your control panel
– Cannot configure an AUX102
– Cannot configure AUX101 outputs
– AUX101 inputs can only be configured
to Switch–Active Low
To determine which control panel version is in-
cluded in your installation, use one of the following
methods.
� Upon initial power-up, the message “Estab-
lishing communication with control” is dis-
played (see Figure 4). This menu also dis-
plays the screen’s software part number and
version.
FIGURE 4. ESTABLISHING COMMUNICATIONS
MESSAGE
� The screen’s software part number is also
displayed in the “About Display” screen in
the History / About submenus (see Figure
5). The first History / About submenu is dis-
played when the (2) button is pressed on the
Service Menu (see Figure 6).
Page 9 of 45
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HISTORY / ABOUT MENUS
SCREEN’S SOFTWARE PART NUMBER
IF P/N = 3266652, GO TO PAGE 14.
FOR ALL OTHER SCREEN SOFTWARE
PART NUMBERS, GO TO PAGE 15.
FIGURE 5. HISTORY / ABOUT MENUS
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AUX101/AUX102 CONTROL PANEL
CONFIGURATION
The very first time the I/O Module is used, all inputs
are disabled and unconfigured and all outputs are
set to their default settings. The sender configura-
tion menus are not displayed unless inputs are
configured as senders.
NOTE: If the PC service tool is used to configure
the I/O Module differently than what is
available through the control panel, “N/A”
is displayed in the value fields.
The I/O Module menus are included with the Ser-
vice menus (see Figure 6).
1. To view the first Service menu from any of the
Operator menus, simultaneously press the 
and selection buttons for two seconds.
2. Press the (1) button on the first Service menu
to view the Setup Password menu.
3. Enter the Setup password.
a. With the first character highlighted, press
the button below to the + or – symbols un-
til the value reads “5.”
b. Press the arrow selection button to
move to the next numeric character.
c. Press the button below the + or – symbols
until the value reads “7.”
d. Press the arrow selection button to
move to the next numeric character.
e. Press the button below the + or – symbols
until the value reads “4.”
f. After you have completed entering the
password, press the arrow selection but-
ton . The first main Setup menu is dis-
played.
NOTE: If the password is not entered or is en-
tered incorrectly, you will be able to
view the menus but the CONFIG and
ADJUST buttons will be blacked out
and you will not be able to change any
of the values/parameters.
After the correct password is entered, it is
remembered until five minutes of button
inactivity elapses. If this happens, you will
have to re-enter the password to access
and change the Setup menus.
4. Press the (1) button to view the first Genset
Service menu.
5. Press the selection button to view the sec-
ond Genset Service menu.
6. Press the (6) button to view the first I/O Mod-
ule menu.
NOTE: If the (6) button is not displayed, the
AUX101 is not connected to the network.
Adjusting Values/Parameters
Once the correct password has been entered and
you have navigated to the first I/O Module menu,
use the following guidelines to configure the I/O
Module.
1. Press the buttons above the and sym-
bols in the digital display to navigate between
submenus.
2. For sensors that have more than one item that
needs needs to be configured, press the
CONFIG selection button.
3. Press the ADJUST selection button to select
the first parameter or value to be changed.
4. Press the + or – selection buttons to adjust val-
ues or select parameters.
5. Press the arrow selection button to navi-
gate to the next or previous adjustable value
or parameter.
6. After adjusting values/selecting parameters,
press the SAVE button to save your settings.
NOTE: If the button is pressed before
pressing the SAVE button, the
changes are not saved.
7. Press the button to return to the previous
main menu.
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ENTER THE 
PASSWORD “574”
FIGURE 6. ACCESS TO I/O MODULE SUBMENUS
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I/O MODULE SUBMENUS
The I/O Module menus are available by pressing
the (6) button on the second Genset Service menu
(see Figure 6).
The I/O Module menus consist of three basic sub-
menus (see Figure 7).
� Network Inputs – Up to 12 network inputs
can be configured (8 with the Base I/O Mod-
ule plus an additional 4 with the Expansion
I/O Module).
� Relay Outputs – Up to 16 relay outputs can
be configured (8 with the Base I/O Module
plus an additional 8 with the Expansion I/O
Module).
� Senders – If any sensor input is defined as a
sender (available with inputs 3 thru 6), the
sender can be configured for one of the 6
available types.
Page 13 of 45
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I/O MODULE SUBMENUS
GO TO PAGE 16 GO TO PAGE 33
GO TO PAGE 37
FIGURE 7. I/O MODULE SUBMENUS
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NETWORK INPUTS (CONTROL PANELS
WITH SCREEN SOFTWARE P/N 3266652)
This section describes the Network Input menus
available only with control panels with screen soft-
ware P/N 3266652. For all other control panels, go
to page 15.
Figure 8 illustrates the configuration menu for In-
put 1 when using control panel software part num-
ber 3266652. The configuration menus are the
same for all eight AUX101 inputs. Table lists the
configuration options for the eight inputs.
AUX102 inputs cannot be configured using a con-
trol panel with software part number 3266652.
I/O MODULE INPUT SUBMENUS
(Control Panels with Screen Software P/N 3266652)
FIGURE 8. I/O MODULE INPUT SUBMENUS (CONTROL PANEL SOFTWARE P/N 3266652)
TABLE 2. NETWORK INPUT CONFIGURATION OPTIONS (CONTROL PANEL SOFTWARE P/N 3266652)
Input Type Event Type Text
All Switch – Active Low Event, Warning, or Shutdown Adjustable
Page 15 of 45
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NETWORK INPUTS (ALL CONTROL
PANELS EXCEPT THOSE WITH SCREEN
SOFTWARE P/N 3266652)
This section describes the Network Input menus
available with all control panels, except those with
control panel screen software P/N 3266652. If your
installation uses screen software P/N 3266652, go
to page 14.
The I/O Module Input menus are available by
pressing the (1) button on the I/O Module #0 menu
(see Figure 7).
NOTE: Inputs 9 thru 12 can be configured only if
an AUX102 Expansion I/O Module is con-
nected to the AUX101.
NOTE: If the PC service tool is used to configure
the I/O Module differently than what is
available through the control panel, “N/A”
is displayed in the value fields. Inputs can
still be configured through the control pan-
el, but only as Switch – Active Low.
When paralleling with generators that are operating
in droop mode, the voltage or speed bias menus of
inputs 1 and 2 can be used to operate the control in
droop mode. To use this feature, make sure that the
PowerCommand controls that are set up to operate
in droop mode include the paralleling option
(H532). For more information on droop paralleling,
refer to the Genset with PCC3100 Digital Parallel-
ing Operation/Service Manual (900–0524).
Input 1 Configuration
The first Input Sensor menu is used to selectthe
switch type and to set the voltage bias (see Figure
9, sheet 1). When the CONFIG button on the I/O
Input 1 menu is selected, a menu is displayed with
access to the Switch and Voltage Bias submenus.
Switch
The Switch submenus are used to select the event
type, description, and logic.
� Type: Enter the event type (Event, Warning,
or Shutdown, default = Warning).
� Enter a brief description of the event (up to
32 characters).
� Select the event logic – Active Low or Active
High (default = Active Low).
Voltage Bias
The Voltage Bias submenu is used to enter the
voltage bias scale. This parameter sets the mini-
mum and maximum voltage bias.
� Scale: Enter the number of volts (0–99 volts,
default = 0 volts).
NOTE: 10V, for example, means that the volt-
age bias is +/–10V.
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I/O MODULE NETWORK INPUT SUBMENUS
A
AA
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 1 OF 10)
Page 17 of 45
C693b
Input 2 Configuration
The second Input Sensor menu is used to select
the switch type and to set the speed bias (see Fig-
ure 9, sheet 2). When the CONFIG button on the
I/O Input 2 menu is selected, a menu is displayed
with access to the Switch and Speed Bias subme-
nus.
Switch
The Switch submenus are used to select the event
type, description, and logic.
� Type: Enter the event type (Event, Warning,
or Shutdown, default = Warning).
� Enter a brief description of the event (up to
32 characters).
� Select the event logic – Active Low or Active
High (default = Active Low).
Speed Bias
The Speed Bias submenu is used to enter the
speed bias scale.
� Scale: Enter the number of RPM (0–200
RPM, default = 0 RPM). This parameter sets
the minimum and maximum speed bias
based on an input voltage to the AUX101 of
0–5V.
NOTE: 120 RPM, for example, means that
the speed bias is +/–120 RPM.
Page 18 of 45
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B
AI/O MODULE NETWORK INPUT
SUBMENUS (Continued)
AA
BB
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 2 OF 10)
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Input 3 thru Input 6 Configuration
The third thru sixth Input Sensor menus are used to
select the switch type and to select the sender
name and type (see Figure 9, sheets 3 thru 6).
When the CONFIG button on the I/O Input 3, 4, 5,
or 6 menu is selected, a menu is displayed with ac-
cess to the Switch and Sender submenus.
Switch
The Switch submenus are used to select the event
type, description, and logic.
� Type: Enter the event type (Event, Warning,
or Shutdown, default = Warning).
� Enter a brief description of the event (up to
32 characters).
� Select the event logic – Active Low or Active
High (default = Active Low). Examples are
shown in Figure 12.
Sender
The Sender type submenu is used to select the
type of sender.
� Select one of the six available senders (Oil
Temp, Exhaust Temp, Ambient Temp, Fuel
Level, Alternator RTD, or Intake Manifold,
default = Oil Temp). Picking a sender type
sets the current source for that sender. Re-
fer to the sender connections shown in Fig-
ure 12.
� Type: Enter the fault type (Warning or Shut-
down, default = Warning).
Page 20 of 45
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B
C
I/O MODULE NETWORK INPUT
SUBMENUS (Continued)
BB
CC
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 3 OF 10)
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C
D
I/O MODULE NETWORK INPUT
SUBMENUS (Continued)
CC
DD
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 4 OF 10)
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D
E
I/O MODULE NETWORK INPUT
SUBMENUS (Continued)
DD
EE
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 5 OF 10)
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E
F
I/O MODULE NETWORK INPUT
SUBMENUS (Continued) EE
FF
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 6 OF 10)
Page 24 of 45
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Input 7 and Input 8 Configuration
The seventh and eighth Input Sensor menus are
used to select the switch type (see Figure 9, sheets
7 and 8). When the CONFIG button on the I/O Input
7 and 8 menu is selected, a menu is displayed with
access to the Switch submenus.
Switch
The Switch submenus are used to select the event
type, description, and logic.
� Type: Enter the event type (Event, Warning,
or Shutdown, default = Warning).
� Enter a brief description of the event (up to
32 characters).
� Select the event logic – Active Low or Active
High (default = Active Low).
Page 25 of 45
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I/O MODULE NETWORK INPUT
SUBMENUS (Continued) F
G
FF
GG
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 7 OF 10)
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I/O MODULE NETWORK INPUT
SUBMENUS (Continued) G
H
GG
HH
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 8 OF 10)
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C693b
Input 9 thru Input 12 Configuration
The ninth thru twelfth Input Sensor menus are only
available if your installation includes an AUX102.
These inputs are used to select the switch type
(see Figure 9, sheets 9 and 10).
� Type: Enter the event type (Event, Warning,
or Shutdown, default = Warning).
� Enter a brief description of the event (up to
32 characters).
� All switches are set to be Active Low.
Page 28 of 45
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I/O MODULE NETWORK INPUT
SUBMENUS (Continued)
H
J
JJ
HH
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 9 OF 10)
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I/O MODULE NETWORK INPUT
SUBMENUS (Continued)
J JJ
FIGURE 9. I/O MODULE INPUT SUBMENUS (SHEET 10 OF 10)
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C693b
NETWORK INPUT VIEW SCREENS
After a network input has been completely config-
ured, its view screen displays the text description
of the input and its current value.
A network input that is defined as a switch input
displays a text description that can be modified
with its configuration menu. Its value is displayed
as either “Active” or “Inactive.”
A network input that is defined as a bias input or
sender input displays a text description that cannot
be modified and its real value in engineering units.
Table 3 lists the configuration options for each net-
work input on all control panel software versions
except for 3266652.
TABLE 3. NETWORK INPUT CONFIGURATION OPTIONS
(ALL CONTROL PANEL SOFTWARE EXCEPT P/N 3266652) 
Input Type Event Type (Code) Text
1 Switch – Active Low or High Event (163), Warning (226), or Shutdown (84) Adjustable1
Voltage Bias Shutdown if Out of Range (102) “Voltage Bias”
2 Switch – Active Low or High Event (164), Warning (227), or Shutdown (85) Adjustable2
Speed Bias Shutdown if Out of Range (103) “Speed Bias”
3 Switch – Active Low or High Event (165), Warning (228), or Shutdown (86) Adjustable3
Sender – Oil Temp Warning (238) or Shutdown (96) “Oil Temp”
Sender – Exhaust Temp Warning (240) or Shutdown (97) “Exhaust Temp”
Sender – Ambient Temp Warning (242) or Shutdown (98) “Ambient Temp”
Sender – Fuel Level Warning (244) or Shutdown (99) “Fuel Level”
Sender – Alternator Temp Warning (246) or Shutdown (100) “Alternator RTD”
Sender – Intake Manifold Temp Warning (248) or Shutdown (101) “Intake Manifold”
4 Switch – Active Low or High Event (166), Warning (229), or Shutdown (87) Adjustable4
Sender – Oil Temp Warning (238) or Shutdown (96) “Oil Temp”
Sender – Exhaust Temp Warning (240) or Shutdown (97) “Exhaust Temp”
Sender – Ambient Temp Warning (242) or Shutdown (98) “Ambient Temp”
Sender – Fuel Level Warning (244) or Shutdown (99) “Fuel Level”
Sender – Alternator Temp Warning (246) or Shutdown (100) “Alternator RTD”
Sender – Intake Manifold Temp Warning (248) or Shutdown (101) “Intake Manifold”
5 Switch – Active Low or High Event (167), Warning (230), or Shutdown (88) Adjustable5
Sender – Oil Temp Warning (238) or Shutdown (96) “Oil Temp”
Sender – Exhaust Temp Warning (240) or Shutdown (97) “Exhaust Temp”
Sender – Ambient Temp Warning (242) or Shutdown (98) “Ambient Temp”
Sender – Fuel Level Warning (244) or Shutdown (99) “Fuel Level”
Sender – Alternator Temp Warning (246) or Shutdown (100) “Alternator RTD”
Sender – Intake Manifold Temp Warning (248) or Shutdown (101) “Intake Manifold”
Page 31 of 45
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TABLE 3. NETWORK INPUT CONFIGURATION OPTIONS
(ALL CONTROL PANEL SOFTWARE EXCEPT P/N 3266652) (CONT.)
Input TextEvent Type (Code)Type
6 Switch – Active Low or High Event (168), Warning (231), or Shutdown (89) Adjustable6
Sender– Oil Temp Warning (238) or Shutdown (96) “Oil Temp”
Sender – Exhaust Temp Warning (240) or Shutdown (97) “Exhaust Temp”
Sender – Ambient Temp Warning (242) or Shutdown (98) “Ambient Temp”
Sender – Fuel Level Warning (244) or Shutdown (99) “Fuel Level”
Sender – Alternator Temp Warning (246) or Shutdown (100) “Alternator RTD”
Sender – Intake Manifold Temp Warning (248) or Shutdown (101) “Intake Manifold”
7 Switch – Active Low or High Event (169), Warning (232), or Shutdown (90) Adjustable
8 Switch – Active Low or High Event (170), Warning (233), or Shutdown (91) Adjustable
9 Switch – Active Low Event (171), Warning (234), or Shutdown (92) Adjustable
10 Switch – Active Low Event (172), Warning (235), or Shutdown (93) Adjustable
11 Switch – Active Low Event (173), Warning (236), or Shutdown (94) Adjustable
12 Switch – Active Low Event (174), Warning (237), or Shutdown (95) Adjustable
Page 32 of 45
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RELAY OUTPUTS
Relay Output menus are available with all control
panels, except those with control panel screen
software P/N 3266652.
The I/O Module Relay Output menus are available
by pressing the (2) button on the I/O Module #0
menu (see Figure 7). The very first time the I/O
Module is used, all outputs are set to their default
settings (see page 2).
NOTE: Outputs 9 thru 16 cannot be configured un-
less the AUX102 is connected to the
AUX101.
Outputs 1–3 and 5–16
The menus for outputs 1, 2, 3, and 5 thru 16 are
identical (see Figure 10, sheet 1). Each of these
menus allows you to select a fault code number.
When the fault code number is entered, the fault
description is displayed.
Page 33 of 45
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I/O MODULE RELAY OUTPUT SUBMENUS
A
B
FIGURE 10. I/O MODULE OUTPUT SUBMENUS (SHEET 1 OF 2)
Page 34 of 45
C693b
Output 4
The Output 4 menu allows for a total of three differ-
ent faults being Or’d together (see Figure 10, sheet
2). If any of the faults are active, then Output 4 is
active. When the fault code number is entered in
each of the three Or’d faults, the fault descriptions
are displayed.
NOTE: After making any adjustments on the three
fault menus, make sure your press the
SAVE button on the individual fault menus
as well as on the main Or’d fault menu.
Page 35 of 45
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A
I/O MODULE RELAY OUTPUT SUBMENUS (Continued)
B
RETURN TO
PAGE 33
FIGURE 10. I/O MODULE OUTPUT SUBMENUS (SHEET 2 OF 2)
Page 36 of 45
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SENDERS
Senders can be configured with all control panels,
except those with control panel screen software
P/N 3266652.
The I/O Module Senders menus are available by
pressing the (3) button on the I/O Module #0 menu
(see Figure 7). The Sender Configuration menus
allow you to adjust the fault thresholds and delays
for each type of sender input that is available. The
Fuel Level sender also requires that resistance of
the sender with a full fuel tank be entered.
If no inputs are configured to be senders, the mes-
sage “No Defined Senders!” is displayed.
Oil Temperature
� High Warning Threshold: Enter the high
warning threshold (–40 to 300 degrees
Fahrenheit, default = 210 degrees).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
Exhaust Temperature
� High Warning Threshold: Enter the high
warning threshold (–40 to 900 degrees
Fahrenheit, default = 210 degrees).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
Ambient Temperature
� High Warning Threshold: Enter the high
warning threshold (–40 to 300 degrees
Fahrenheit, default = 210 degrees).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
Page 37 of 45
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I/O MODULE SENDERS SUBMENUS
OR
A
CONTINUED
ON PAGE 39
B
FIGURE 11. I/O MODULE SENDERS SUBMENUS (SHEET 1 OF 3)
Page 38 of 45
C693b
Fuel Level
� Low Warning Threshold: Enter the low warn-
ing threshold (0.0 to 99.9 percent, default =
5.0 percent).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
� 100% Resistance: Enter the resistance val-
ue for when the tank is full (600 to 2500
ohms, default = 2200 ohms).
Page 39 of 45
C693b
RETURN TO
PAGE 37
B
A
I/O MODULE SENDERS SUBMENUS (Continued)
CONTINUED
ON PAGE 41
FIGURE 11. I/O MODULE SENDERS SUBMENUS (SHEET 2 OF 3)
Page 40 of 45
C693b
Alternator RTD
� High Warning Threshold: Enter the high
warning threshold (–40 to 300 degrees
Fahrenheit, default = 210 degrees).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
Intake Manifold Temperature
� High Warning Threshold: Enter the high
warning threshold (–40 to 300 degrees
Fahrenheit, default = 210 degrees).
� Time Delay: Enter the time delay (0 to 15
seconds, default = 5 seconds).
Page 41 of 45
C693b
RETURN TO
PAGE 37
BA
I/O MODULE SENDERS SUBMENUS (Continued)
SEE
PAGE 39
FIGURE 11. I/O MODULE SENDERS SUBMENUS (SHEET 3 OF 3)
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THIS PAGE INTENTIONALLY LEFT BLANK
Page 43 of 45
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No. 630-3142 Sh 1 of 2
Rev. A Sys: HP
Modified 7/2005
 AUX101 SWITCHED INPUTS
 ACTIVE LOW ACTIVE HIGH
SWITCH SWITCH INPUT REFERENCE SWITCH INPUT REFERENCE
8 J11-16 J11-15 J11-16 J10-8
7 J11-14 J11-13 J11-14 J10-8
6 J11-12 J11-11 J11-12 J10-8
5 J11-10 J11-9 J11-10 J10-7
4 J11-8 J11-7 J11-8 J10-7
3 J11-6 J11-5 J11-6 J10-7
 AUX101 SENDERS
SENDER SENDER CURRENT GROUND
INPUT SOURCE REFERENCE
6 J11-12 J10-6 J11-11
5 J11-10 J10-5 J11-9
4 J11-8 J10-4 J11-7
3 J11-6 J10-3 J11-5
FIGURE 12. I/O MODULE WIRING DIAGRAM
Page 44 of 45
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No. 630-3142 Sh 2 of 2
Rev. A Sys: HP
Modified 7/2005
FIGURE 12. I/O MODULE WIRING DIAGRAM
Page 45 of 45
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No. 630-2926 Sh 1 of 1
Rev. D Mod Sys: HP
Modified 5/2005
FIGURE 13. 1301 CONTROL WIRING DIAGRAM