PowerCommand
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Serial Communications Kit
Installation Instructions
Powerful Solutions
Printed in U.S.A. 9000522B
1199
Table of Contents
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SECTION TITLE PAGE
SAFETY PRECAUTIONS ii, iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools Required 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 PCC SERIAL COMMUNICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Communications 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 HARDWARE INSTALLATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Serial Communications Interface Board Installation 3-2. . . . . . . . . . . . . .
PowerCommand Cable Interface Installation 3-4. . . . . . . . . . . . . . . . . . . . . . . .
Wiring Connections 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 ALARM SETUP 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Section 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCC Setup Menu for Alarm Reporting 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Checkout 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN
DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/
OR MECHANICAL SERVICE.
i
Safety Precautions
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The PowerCommand Serial Communications Interface Board can be used to remotely monitor and
operate generator sets. All of the safety precautions
for that equipment must observed. Refer to the Operator’s Manual for the equipment that is being remotely monitored and controlled for important safety precautions.
The following symbols, found throughout this
manual, alert you to potentially dangerous conditions to the operator, service personnel, or the
equipment.
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING
safe practice which can result in severe personal injury or death.
CAUTION
safe practice which can result in personal injury
or product or property damage.
This symbol refers to a hazard or un-
This symbol refers to a hazard or un-
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, dis-
connect battery charger from its AC source,
then disconnect starting batteries, negative (-)
cable first. 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 vi-
cinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry
can become caught in moving parts. Jewelry
can short out electrical contacts and cause
shock or burning.
• If adjustment must be made while the unit is
running, use extreme caution around hot manifolds, moving parts, etc.
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.
• Use extreme caution when working on electri-
cal 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.
• Jewelry is a good conductor of electricity and
should be removed before working on electrical equipment.
ii
MEDIUM VOLTAGE GENERATOR SETS
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(601V to 15kV)
• Medium voltage acts differently than low volt-
age. Special equipment and training are 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.
• Do not work on energized equipment. Unau-
thorized personnel must not be permitted near
energized equipment. Due to the nature of medium voltage electrical equipment, induced
voltage can remain 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
PowerCommand Software for Windows
•
can remotely start and stop a genset. Make
certain that all appropriate personnel are notified before remotely operating equipment and
make them aware of any equipment that can be
energized automatically.
• 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.
PowerCommand is a trademark of Onan Corporation
Windows is a registered trademark of Microsoft
Corporation.
iii
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iv
1. Introduction
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ABOUT THIS MANUAL
These instructions cover installation of the components and wiring required for PowerCommand
Control (PCC) serial communications. The kit includes the PCC Serial Communications Interface
Board, the PowerCommand Cable Interface and
two cables. The PCC Serial Communications Interface Board provides direct serial communications
with the PCC (installation of a control type network
is not needed).
CAUTION
Electrostatic discharge will damage
circuit boards and components. Do not remove
the circuit board from the antistatic shipping
bag until you are grounded to the PCC with a
wrist strap.
The PCC operating software must be version
2.00 or higher for the PCC Serial Communications
Interface Board to communicate with the PCC.
Check the version on the display menu. If the version number is below 2.00, obtain and install an
EPROM upgrade kit before proceeding with this
installation. Follow the installation instructions provided with the EPROM kit.
The PCC Serial Communications Interface Board
allows a host PC with PowerCommand for Windows to communicate, via a serial connection, with
the PCC.
The PowerCommand Cable Interface provides a
junction box between the twisted pair from TB1 and
the serial cable from the host PC or modem.
The null modem cable is used to connect directly to
a host PC, and the Modem cable is used to connect
to a modem.
This manual is intended for service personnel with a
basic understanding of serial communications who
are also qualified to perform service on generator
sets. Review the entire manual before starting the
installation.
Section 2 provides an overview of PCC serial communications. Section 3 describes the hardware
installation. Section 4 covers the alarm setup.
Abbreviations
ACK Acknowledgement
NAK Negative Acknowledgement
PC Personal Computer
PCC PowerCommand
PCW PowerCommand
SCT Serial Configuration Tool
Control
for Windows
SPECIAL TOOLS REQUIRED
• Grounding wrist strap with grounding clip
• Serial Communication Configuration Tool
Software
• PowerCommand
version 1.1) Only required if an installation
checkout will be preformed
PowerCommand is a trademark of Onan Corporation.
1997 Onan Corporation
for Windows (minimum
1-1
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1-2
2. PCC Serial Communications
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SERIAL COMMUNICATIONS
The PCC serial protocol provides simple commands for reading bytes from–and writing bytes to–
the PCC. In the single set software, a protocol command is provided for alarm reporting in direct or remote connections. The serial communications interface does not support the Emergency stop feature in PCW.
The PCC has the means of reporting alarm events
as they transpire. When enabled, it is an event-driven real-time alarm reporting protocol. This means
anytime the PCC senses a warning or fault, it has
the ability to initiate communications to report the
event to the host. This is accomplished either
through remote connections via a modem or a direct serial link. Refer to Figures 2-1 and 2-2.
The PCC has three lines for communications that
are available at the Customer Interface Terminal
Block:
NET_DATA 2 (TB1–15 [TX]) – Transmit
NET_DATA 1 (TB1–14[RX]) – Receive
NET_POWER (TB1–13[GND]) – Ground
There are no handshaking or control lines available.
The PCC’s serial communication is interrupt-driven. Any time data is received at the PCC, an interrupt is generated for the microprocessor to handle
the data. Once all the data is received, it is checked
for validity and errors. If the command was valid
and the data was without error, the command is executed and the proper data is returned. If the communication was unsuccessful, a NAK (negative acknowledgment) or no data will be returned. The
host must then re-transmit the command.
The PCC does incorporate a simple form of error
checking. The PCC uses a longitudinal redundancy
check (LRC), which is the exclusive–OR (XOR) of
all the bytes in the packet to be sent. This byte is
attached to the end of the packet.
PCC Serial Interface
The PCC Serial Communication Protocol is designed for two conditions of connection:
1. The PCC is directly connected through a PC
serial port (direct serial connection). Figure
2-1.
2. The PCC is remotely connected via modems
and the telephone line to the host PC (remotely
connected). Figure 2-2.
PowerCommand Control
PowerCommand
Cable Interface
Serial Cable
Twisted Pair
(From Connection
Box TB1)
FIGURE 2-1. DIRECT SERIAL COMMUNICATION
(DB9 to DB9)
2-1
Host Computer
PowerCommand Control
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PowerCommand
Cable Interface
Twisted Pair
(From Connection
Box TB1)
Serial Cable
(DB9 to
DB25)
MODEM
Host Computer
Telephone
Line
MODEM
Serial Cable
(DB25 to
DB9)
FIGURE 2-2. REMOTE SERIAL COMMUNICATION VIA MODEMS
2-2
3. Hardware Installation
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OVERVIEW
This section describes installation of the PowerCommand Serial Communications Interface Board
and the Serial Cable Interface Board.
The PCC Serial Communications Interface Board
must be used with PCC operating software version 2.00 or higher for all models. Check the ver-
sion on the display menu. If the version number is
below 2.00, obtain and install an EPROM upgrade
kit before proceeding with this installation. Follow
the installation instructions provided with the
EPROM kit.
DESCRIPTION
The Serial Communications Interface Board provides customers with an electrically isolated
(EIA–232) RS232 serial communications interface
to the PCC.
When the PowerCommand Serial Communications
Interface Board is installed, the PCC control will no
longer enter the sleep mode.
The Serial Cable Interface Board is used to provide
a DB9 cable connection. This connection can be
used for either direct serial communication with a
host computer or for remote serial communication
via a modem (Figures 2-1 and 2-2).
LOCATION
The PowerCommand Serial Communications Interface Board is mounted inside the PCC cabinet on
top of the analog board (Figure 3-1). The Serial
Cable Interface Board is located outside the generator set connection box. Refer to the installation instruction section.
CAUTION
Electrostatic discharge will damage
circuit boards. Do not remove the circuit board
from the antistatic shipping bag until you are
grounded to the PCC with a wrist strap.
Circuit Board Handling Precautions
To help prevent circuit board damage due to electrostatic discharge (ESD), a grounding wrist strap
must be worn when handling the circuit board. (The
wrist strap does not provide a direct short to ground,
it is typically rated at approximately 1 megohm to
ground.)
Attach the wrist strap clip to a clean unpainted surface of the control box (see Figure 3-1) and place
the strap around your wrist before handling a circuit
board.
3-1
PCC SERIAL COMMUNICATIONS
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INTERFACE BOARD INSTALLATION
1. Place the genset Run/Off/Auto switch, on the
control panel, in the Off position.
2. Disconnect the battery charger (if applicable).
Remove all electrical supply sources.
CAUTION
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 system.
3. Disconnect the genset starting battery
cable(s). Disconnect the negative (–) cable(s)
first to reduce the risk of arcing.
WARNING
Accidental starting of the genset while working on it can cause severe
personal injury or death. Prevent accidental starting by disconnecting the starting
battery cables. T o reduce the risk of arcing,
disconnect the negative (–) cable first.
When reconnecting, connect the negative
(–) cable last.
Make certain battery area has been wellventilated before servicing battery. Arcing
can ignite explosive hydrogen gas given off
by batteries, causing severe personal injury. Make certain hydrogen gas, engine fuel,
and other explosive fumes are fully dissipated. This is especially important if battery
has been connected to a battery charger.
ANALOG
BOARD
A33
WRIST STRAP
FIGURE 3-1. PREPARING FOR INSTALLATION
4. Open the control box door. Connect the wrist
strap ground clip as shown in Figure 3-1.
5. Use a Phillips screwdriver to remove the four
leftmost analog board mounting screws shown
in Figure 3-1.
6. Install four new standoffs in place of the analog
board mounting screws removed in step 5
(Figure 3-2). Tighten the standoffs securely.
FIGURE 3-2. INSTALLING STANDOFFS
3-2
7. Mount the board as shown in Figure 3-3, using
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the screws removed from the analog board.
Tighten the mounting screws securely.
8. Orient the J6 harness connector as shown in
Figure 3-4. Push the J6 plug securely into the
connector on the engine interface board.
9. Spread locking tabs apart on the J7 connector .
Fold the ribbon cable, as shown in Figure 3-4,
align key on plug with socket cutout. Insert the
J7 harness plug into the J7 connector on the
engine interface board. Press in on the harness
connector, at the location indicated by the arrow, until the locking tabs lock into place.
10. Proceed to PowerCommand Cable Interface
Installation.
ENGINE INTERFACE
LOCKING
TABS
BOARD A31
FIGURE 3-3. BOARD MOUNTING
ALIGN KEY
WITH CUTOUT
FOLD RIBBON
CABLE HERE
J7 CONNECTOR
J6 CONNECTOR
FIGURE 3-4. INSTALLING J6 AND J7 CONNECTORS
3-3
POWERCOMMAND CABLE INTERFACE
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INSTALLATION
Location
Choose a clean, vibration-free mounting surface
within 100 ft. (30.5 M) of the generator set. Avoid
locations that are hot, damp or dusty . The temperature range must not exceed –40°F (–40°C) to 158°F
(70°C).
The board is designed for panel mounting within
other equipment enclosures. The board is potted in
a molded shell.
2.95 (75)
Mounting
Figure 3-5 shows the outline dimensions. The outside dimensions do not include clearance for wire
connections.
If mounting the module to a wall, make sure that no
wires, plumbing, gas or exhaust lines run behind the
wall before drilling the mounting holes.
0.875 (22.2)
0.51 (13)
3.94 (100)
3.15 (80)
0.39 (10)
2.17 (55)0.39 (10)
0.47 (12)
FIGURE 3-5. POWERCOMMAND CABLE INTERFACE OUTLINE DRAWING
3-4
0.23 (5.9)
DIMENSIONS IN
INCHES (mm)
CUSTOMER CONNECTIONS TB1
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OPTIONAL SHIELD
CONNECTION
TB115 (TX)
TB114 (RX)
TB113 (GND)
POWERCOMMAND CABLE
INTERFACE BOARD
MOUNTING SCREW
UNSHIELDED 22 AWG UL LEVEL IV OR EIA
CAT. 4 TWISTED PAIR COMMUNICATION WIRE
FIGURE 3-6. GENSET (TB1) TO POWERCOMMAND CABLE INTERFACE CONNECTIONS SCHEMATIC
WIRING CONNECTIONS
22 AWG UL level IV or EIA CAT . 4 twisted pair communication wire.
Serial data wiring connections are made between
TB1 in the accessory box (Figure 3-7) and TB1 on
the PowerCommand Cable Interface. Refer to Figure 3-6 for the connection diagram. Use unshielded
For Local Connection to Host PC:
Cable (Figure 3-8).
For Remote Connection via Modem:
Cable (Figure 3-8).
Use Null Modem
Use Modem
3-5
TB1-1
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HC 6/7
TB1-1
HC 4/5
FIGURE 3-7. ACCESSORY BOX
3-6
MODEM CABLE
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(DB to DB25)
72 ± 6
(183 ± 15)
NULL MODEM CABLE
(DB9 to DB9)
FIGURE 3-8. WIRE HARNESS DRAWINGS
TABLE 3-1. RS232 (SERIAL) D CONNECTOR
PINOUTS
25 – Pin D Connector 9 – Pin D Connector
Pin Descriptor Pin Descriptor
2 TX 1 DCD
3 RX 2 RX
4 RTS 3 TX
5 CTS 4 DTR
6 DSR 5 GND
7 GND 6 DSR
8 DCD 7 RTS
20 DTR 8 CTS
22 RI 9 RI
72 ± 6
(183 ± 15)
DIMENSIONS IN
INCHES (cm)
3-7
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3-8
4. Alarm Setup
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ABOUT THIS SECTION
This section describes procedures for using the
PCC setup menu for Alarm Reporting. In order to
perform this setup the PowerCommand Serial
Communications Interface Board must be installed.
NOTE: For remote alarm reporting, the setup must be
performed with the Serial Configuration Tool (SCT).
Use the instructions provided with the SCT software.
Also use SCT for installing a password (optional).
The password default is eight nulls (∅).
PCC SETUP MENU FOR ALARM
REPORTING
The PCC Alarm Reporting Menu (Figure 4-1) will
only appear if the serial communication module is
installed.
SITE ID, and PHONE #1 are editable fields in the
Setup Menu. Refer to the generator set service
manual Control Service and Calibration section for
instructions on entering the Setup Menu.
A maximum of 8 digits can be entered for SITE ID,
and 16 digits for PHONE #1. A carriage return must
be entered as a termination character at the end
of the phone number. The symbol for a carriage return is a ‘ê’ (an ‘e’ with a cap on it). Scroll past the
numbers to reach the special characters. Without
this termination character, the phone number is invalid and the PCC will not dial out.
NOTE: When SCT is used to configure the Phone #1,
the termination character is automatically added.
PCW COMM ON/OFF:
Enables or disables the
alarm reporting protocol.
MODEM COMM ON:
Enables remote communica-
tion using the alarm reporting protocol.
MODEM COMM OFF:
Enables direct serial con-
nection using the alarm reporting protocol.
LANGUAGE
ENGLISH >>
PCW COMM.
−
ON >>
MODEM COMM
−
ON >>
00000000
SITE ID >>
0000000000000000
PHONE # 1
FIGURE 4-1. PCC ALARM REPORTING SETUP MENU
PCW COMM.
−
OFF >>
MODEM COMM
−
OFF >>
00000000
SITE ID >>
SAVE
EXIT >>
4-1
Direct Serial Communication
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PHONE #1 can be entered into the PCC either by
the service tool (SCT) or the PCC Setup menu.
From the PCC Setup Menu, set PCW COMM to ON
and set the MODEM COMM to OFF. This allows the
PCC Setup Variables(for Alarm Reporting)
PCC to enable the alarm reporting protocol and initiate the communication in the direct serial connection.
Table 4-1 lists the PCC Setup Variables and pro-
vides a description of how they are configured. Note
three variable (not shown) the MODEM INIT
Remote Serial Communication
STRING, DIAL_PREFIX, and PASSWORD can
only be configured with the Serial Configuration
From the PCC Setup Menu, set both the PCW
COMM and MODEM COMM to ON. A phone number followed by a carriage return (‘ê’) must be entered in PHONE #1. This allows the PCC to enable
the alarm reporting protocol and the PCC to initiate
Tool (SCT). Refer to the instructions provided with
the SCT software.
NOTE: The password default is eight nulls (∅). The
only way it can be changed is with the Serial Configu-
ration Tool (SCT).
the remote communications, such as dialing out
alarms.
TABLE 4-1. PCC SETUP VARIABLES
VARIABLES DESCRIPTION
SITE_ID The site_id is a 8 character (byte) ASCII string, This string is intended to define the
actual genset site location. The site_id is passed as part of the alarm message by
the alarm reporting protocol. e.g. SITE_ID = {“Onan”}
PHONE_NO_1 The Phone No 1 is a 16 character (byte)ASCII string. This string should be num-
bers only, but will take any character the modem will recognize as valid for a dial
string. This string contains the phone number of the location the PCC will call in
case of an alarm. This location should be a Computer with a modem set to auto–
answer. If the phone number is not terminated by a carriage return the PCC will not
call out. Therefore the phone number can be a maximum of 15 digits long with the
last character in the phone string being a carriage return. MODEM COMM in the
Setup menu of the PCC must be set to ON, to enable the PCC to dial out. e.g.
PHONE_NO_1 = {6125745400,0x0D} Note: 0x0D = ‘ê’
4-2
INSTALLATION CHECKOUT
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Record the site ID and phone number for the site. If
used, also record the password, modem init string,
and dial prefix. Keep this information in a safe place.
To checkout the site thoroughly, the installer will
need to have PowerCommand for Windows (PCW)
beginning at version 1.1. Refer to the PCW manual
(900-0365) for instructions on installing and running
PCW. Operate PCW to thoroughly check out the
installation.
If installation problems are detected, make sure that
all electrical connections are making good contact,
check the password (if used), and return to SCT to
check the configuration settings.
If error messages or warnings are displayed in the
PCC display, refer to the appropriate service manu-
al Troubleshooting section.
4-3
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4-4
Cummins Power Generation
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1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-6626
763-528-7229 International Use
Fax: 763-528-7229
Cummins is a registered trademark of Cummins Inc.
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