Instruction Sheet

C715 (Issue 5) 5-2017

Installation Instructions for PCC1301 to PCC1302

Conversion Kit 541−1431
SAFETY PRECAUTIONS
Read these instructions completely and become
familiar with safety warnings, cautions, and proce-
dures before starting the installation.

WARNING Incorrect installation, service, or

parts replacement can result in severe person-
al injury, death, and/or equipment damage. Ser-
vice personnel must be trained and experi-
enced to perform electrical and mechanical
component installations.
CAUTION A generator set control must be
serviced only by technically qualified person-
nel. High voltages are present. These voltages
can cause electrical shock, resulting in person-
al injury.
Even with power removed, improper handling
of components can cause electrostatic dis-
charge and damage to circuit components.
FIGURE 2-1. PCC1302 CONTROL BOARD
WARNING AC voltages and currents present
an electrical shock hazard that can cause se-
GENERAL INFORMATION vere personal injury or death. Incorrect instal-
This Instruction Sheet describes the steps re- lation, service, or parts replacement can result
quired to replace a PCC1301 control with a in severe personal injury, death, and/or equip-
PCC1302 control on gensets. This kit includes the ment damage. Only trained and experienced
following items. personnel are to perform the following proce-
dures.
TABLE 1. PARTS LIST FOR UPGRADE KIT Turn off or remove AC power from the battery char-
Part Description Part Number Qty
ger and then remove the negative (−) battery cable
from the set starting battery. This is to make sure
PCC1302 Control Board 0327−1617−01 1 the set will not start while working on it and to avoid
PCC1301 to PCC1302 Up- 0338−4978 1 circuit board damage, caused by voltage spikes
grade Harness when removing and replacing circuit board con-
(HM Application) nectors.
PCC1301 to PCC1302 Up- 000C−0715 1
grade Manual CAUTION If present, always disconnect a bat-
tery charger from its AC source before discon-
PCC1302 Owner Manual 0900−0661 1
necting the battery cables. Otherwise, discon-
NOTE: If your installation does not include opera- necting the cables can result in voltage spikes
tor panel PN 300−6014, it must be pur- high enough to damage the DC control circuits
chased separately before installing this kit. of the generator set.

Page 1 of 12 Copyright  2017 Cummins Inc.

 WARNING Accidental starting of the genera- 4. Disconnect the generator set starting battery
tor set while working on it can cause severe cables. Disconnect the negative (−) cable first
personal injury or death. Prevent accidental to reduce the risk of arcing.
starting by disconnecting the starting battery
cables (negative [−] first). 5. Disconnect all wiring connections to the
PCC1301 control board.
Make certain the battery area has been well-
ventilated before servicing the battery—Wear 6. Remove the PCC1301 control board.
goggles—Stop the genset and disconnect the
7. Use the existing hardware to install the
charger before disconnecting battery cables.
PCC1302 control board.
Arcing can ignite explosive hydrogen gas giv-
en off by batteries, causing severe personal in- 8. Connect the control harness included in this kit
jury. Arcing can occur when a cable is removed to the control board (see Figures 7 and 8).
or re-attached, or when the negative (−) battery Make the following connections.
cable is connected and a tool used to connect
or disconnect the positive (+) battery cable Harness Connector Control Board Connector
touches the frame or other grounded metal part
of the generator set. Always remove the nega- P17 J17
tive (−) cable first, and reconnect it last. Make P18 J18
certain hydrogen from the battery, engine fuel, P22 J22
and other explosive fumes are fully dissipated. P11 J11
This is especially important if the battery has
P20 J20
been connected to a battery charger.
P25 J25
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- 9. Rewire TB1 as indicated in Table 2.
ing at battery terminals, light switch or other TABLE 2. TB1 WIRING
equipment, flame, pilot lights and sparks can
ignite battery gas. Do not smoke, or switch TB1 Location
Description
trouble light ON or OFF near a battery. Dis- PCC1301 PCC1302
charge static electricity from body before B+ 1 5
touching batteries by first touching a grounded
PCCNet A 2 1
metal surface.
PCCNet B 3 2
KIT INSTALLATION GND 4 3
Ready to Load 5 4
1. Record your PCC1301 control settings and
downloaded feature codes. Use InPower to NOTE: Positions TB1-6 thru TB1-16 are the
create a capture file. same.
NOTE: PCC1302 includes additional fea-
NOTE: Capture file is for reference only, it tures such as Switch B+ Driver and
cannot be used to overlay settings two additional configurable inputs.
on the PCC1302. Refer to the PCC1302 Owner’s
manual for more details.
2. Make sure the control is in the Off mode by
10. Connect a wake-up line to the display.
pressing the button.
a. Remove the loose socket wire (labeled
3. Disconnect the battery charger (if equipped). J1-4) from the harness (connected to
Remove all electrical supply sources. J25-5 − see Figure 8).
b. Plug the wire into location #4 of one of the
WARNING Ignition of explosive battery display’s connectors (see Figure 5).
gases can cause severe personal injury. Do not
smoke or cause any spark, arc, or flame while NOTE: The wire may have to be cut or
servicing batteries. lengthened. Use 18 gauge wire.

Copyright  2017 Cummins Inc. Page 2 of 12

TABLE 3. PARTS LIST FOR RELAY INSTALLATION

Part Description Part Number Qty

Relay (12V) 0307−2968−03 2
Relay (24V) 0307−2968−04 2
Mounting Screws 0812−0079 4
Nuts 0870−0221 4

NOTE: When installing a 0327−1513−01

board, two DC relays need to be
added to the harness to replace the
K7 and K8 relays.

FIGURE 2. ORIGINAL SCHMATIC SHOWING RE-

LAYS ON BOARD

NOTE: Load control by these relays differs

depending on the generator set
model. Due to the unpredictable per-
formance of smaller relays, it is rec-
ommended the 0307−2968−03
(12V) or 0307−2968−04 (24V),
30−Amp relays be used. This should
provide sufficient current to the fuel
shutoff pump and starter.
12. Connect the ground−side of the relay coil to
the J11−21 and connect the positive−side to
the Relay Coil B+ for the Starter Relay (K7)
installation.

FIGURE 1. SHOWN WITH K7 & K8 MOUNTED ON 13. Connect the ground−side of the relay coil to
PCC 1301 J11−22 and connect the positive−side to the
Relay Coil B+ for the Fuel Shut Off Relay (K8).

11. Remove the corresponding wires from the 14. Plug the existing PCC1301 engine harness
connector and manually wire the relays using into the harness included with this kit (J11 and
spade terminals. J13 connectors).

Page 3 of 12 Copyright  2017 Cummins Inc.

FIGURE 3. NEW SCHMATIC SHOWING NEW PIN−
OUT FOR K7 & K8 RELAYS FIGURE 4. VOLTAGE SENSE MODIFICATION

15. Change the voltage sense wiring (see Figure

4). 1 5
2 6
16. Connect the shunt wiring (see Figure 4) to 3 7
J18−1 and J18−2 (see Figure 6). 4 8

J1 or J2
17. Reconnect the generator set starting battery.
Connect the positive cable (+) first.

18. Reconnect the battery charger (if equipped). PIN 4 J2

19. Download the latest calibration into the

PCC1302 and HMI211. Latest calibration files J1
can be downloaded from the InCal website.
FIGURE 5. REAR OF DISPLAY
20. Refer to the settings recorded in step 1 and ad- The PCC1302 control board includes the following
just settings, as necessary. Use the connectors.
PCC1301−02 Feature Conversion Matrix
(available on QuickServe under PowerCom-  TB1 − Customer connections
mand 1.x) to determine the required features  TB15 − Tools interface connections
to be downloaded.
 J11 − Engine connections
 J12 − Genset CT connections
21. Test the installation by starting the genset and
verifying proper operation.  J17 − Field winding connections
 J18 − Field power connections
22. Set the control to the desired operating mode.  J20 − Genset connections
 J22 − Alternator voltage sense connections
23. Refer to the 1302 control Operator/Installation  J25 − Display connections
manual for information on PCC1302 menus.

Copyright  2017 Cummins Inc. Page 4 of 12

 FIGURE 6. PCC1302 CONNECTIONS

J22 (ALTERNATOR J12 (CT TB15 (PC BASED SER-

VOLTAGE SENSE) CONNECTIONS) VICE TOOL)
J17
(FIELD
POWER)
J11 (ENGINE
CONNEC-
TIONS)
J18
(FIELD
POWER)

J20 (GENSET
CONNEC-
TIONS)

J25 (DISPLAY
TB1 (CUSTOMER CONNECTIONS)
CONNECTIONS)
FIGURE 7. PCC1302 CONTROL BOARD CONNECTIONS

Page 5 of 12 Copyright  2017 Cummins Inc.

 FIGURE 8. PCC1302 WIRING HARNESS

Copyright  2017 Cummins Inc. Page 6 of 12

 No. 630-2926 Sh 1 of 1
Rev. J Mod Sys: HP
Modified 2/2015

FIGURE 9. 1301 CONTROL WIRING DIAGRAM

C715
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Copyright  2017 Cummins Inc.
 No. 630-3270 Sh 2 of 4
Rev. − Sys: ProE
Modified

FIGURE 10. 1302 CONTROL WIRING DIAGRAM (SHEET 1 OF 4)

C715
Copyright  2017 Cummins Inc. Page 8 of 12
 No. 630-3440 Sh 2 of 20
Rev. − Sys: ProE
Modified 10/2012

FIGURE 10. 1302 CONTROL WIRING DIAGRAM

(SHEET 2 OF 4)
C715
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Copyright  2017 Cummins Inc.
 No. 630-3270 Sh 3 of 4
Rev. − Sys: ProE
Modified

FIGURE 10. 1302 CONTROL WIRING DIAGRAM

(SHEET 3 OF 4)
C715
Copyright  2017 Cummins Inc. Page 10 of 12
 No. 630-3270 Sh 4 of 4
Rev. − Sys: ProE
Modified

FIGURE 10. 1302 CONTROL WIRING DIAGRAM

(SHEET 4 OF 4)
C715
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Copyright  2017 Cummins Inc.
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C715
Copyright  2017 Cummins Inc. Page 12 of 12