Page 1 of 2 E2010 Cummins Power Generation, Inc. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.

A030Y369 (Issue 1)
4-2010
Instruction Sheet
Installation Instructions for PCC 2300 Base Board V2
SAFETY PRECAUTIONS
Read these instructions completely and become fa-
miliar with safety warnings, cautions, and proce-
dures before starting the installation.
WARNING Incorrect installation, service, or
parts replacement can result in severe personal
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 ser-
viced only by technically qualified personnel.
High voltages are present. These voltages can
cause electrical shock, resulting in personal in-
jury.
Even with power removed, improper handling
of components can cause electrostatic dis-
charge and damage to circuit components.
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. Only trained and experienced
personnel are to perform the following proce-
dures.
Turn off or remove AC power from the battery char-
ger and then remove the negative () battery cable
from the set starting battery. This is to make sure the
set will not start while working on it and to avoid cir-
cuit board damage, caused by voltage spikes when
removing and replacing circuit board connectors.
CAUTION If present, always disconnect a bat-
tery charger from its AC source before discon-
necting the battery cables. Otherwise, discon-
necting 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 per-
sonal injury or death. Prevent accidental start-
ing by disconnecting the starting battery cables
(negative [] first).
Make certain the battery area has been well-ven-
tilated before servicing the batteryWear
gogglesStop the generator set and discon-
nect the charger before disconnecting battery
cables. Arcing can ignite explosive hydrogen
gas given off by batteries, causing severe per-
sonal 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 met-
al 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 dissi-
pated. 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. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
nite 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.
INSTALLATION INSTRUCTIONS
Before you start installation, you should have the
latest version of software for the following compo-
nents:
PCC2300 V2
HMI 220 or HMI 320 (depending on the
installation)
AUX 101
If you do not have the latest version of software for
one or more components, go to the InCal web site to
get it.
Page 2 of 2
A030Y369 (Issue 1)
1. Make sure the generator set is off.
2. Save a capture file from the PCC 2300 V1 base
board.
3. Push one of the Emergency stop buttons, and
wait thirty seconds.
4. Isolate any power supplies (for example, for
heaters or pumps) to the genset. This does not
include the starting battery or battery charger,
which are isolated in the next steps.
5. Turn off and remove power from the battery
charger, if there is one. Disconnect the battery
charger from the starting battery.
6. MAKE CERTAIN EXPLOSIVE BATTERY
GASES ARE DISPELLED FROM BATTERY
COMPARTMENT, and then remove the nega-
tive () battery cable from the starting battery
(for electrical starters).
7. Disable the starter, if it is possible for the genset
to start without the battery (for example, an air
starter). Isolate the starter air supply from the
air start compressor to the engine. Secure the
isolation tap in the Closed position.
CAUTION The air in the compressor-to-engine
air supply line is under pressure. If vented im-
properly, this air can cause personal injury or
equipment damage when it is released. Release
the air so that it does not damage equipment or
injure anyone.
Then, release the air in the compressor-to-en-
gine air supply line so that it does not damage
equipment or injure anyone.
8. Display a suitable Maintenance In Progress
sign prominently.
9. Follow the appropriate lockout/tagout proce-
dures.
10. Physically replace the PCC 2300 V1 base
board with the PCC 2300 V2 base board. You
can reuse the existing hardware.
11. Re-enable the starter, if necessary.
12. Reconnect the negative () battery cable to the
starting battery (for electrical starters).
13. Reconnect the battery charger to the starting
battery, and turn on the power to the battery
charger.
14. Reconnect any other power supplies (for ex-
ample, heaters or pumps).
15. Make sure the generator set is off.
16. Pull out the Emergency stop button, and reset
the Emergency Stop fault, if it occurred.
17. Install the latest version of PCC 2300 V2 soft-
ware on the PCC 2300 V2 base board.
18. Overlay the capture file that you saved in step
1 onto the PCC2300 V2 base board.
19. Install the latest version of HMI 220 or HMI 320
software on the operator panel.
20. If there is an AUX 101, install the latest version
of AUX 101 software on it.
21. Remove any locks or tags, and pick up the
Maintenance In Progress sign.