Instruction Sheet

A041J096 (Issue 3) 11-2016

Installation Instructions for Remote Panel Kits A041J582 (HMI220)

and A041J589 (HMI320)
GENERAL INFORMATION TABLE 1. KIT PARTS
Item Description Qty
These instructions provide the procedure for instal-
1 Display Panel 1
ling a remote control panel.
2 Plug Connector (J28) 1
3 Plug Connector (J29) 1
4 Socket Contact Pins 19

Display
Panel

J28 Connector
FIGURE 1. REMOTE HMI220 CONTROL PANEL

J29 Connector

Socket Contact Pin

FIGURE 3. KIT COMPONENTS

FIGURE 2. REMOTE HMI320 CONTROL PANEL
Verify that the following items are included in the kit.
GENERAL PRECAUTIONS
Read these installation instructions completely and
become familiar with safety warnings, cautions, and
the installation procedure before starting.
Incorrect installation can result in
WARNING
severe personal injury or death and/or equip-
ment failure or damage. This kit must be
installed by service personnel who are trained
and experienced to perform electrical and me-
chanical service.

Copyright 2016 Cummins Inc. Page 1 of 10

Turn off or remove AC power from the battery char- the HMI will be located in will be below 4 _F, (20
ger and then remove the negative () battery cable _C), install an HMI heater (kit A026J556 includes In-
from the set starting battery. This is to make sure the struction Sheet A028X284).
set will not start while working on it.
Isolated Remote Power Supply
CAUTION Always disconnect a battery char-
ger from its AC source before disconnecting the If the voltage drop in the wires is too excessive, due
battery cables. Otherwise, disconnecting the to the wire losses, an isolated remote power supply
cables can result in voltage spikes high enough will need to be installed. Voltage range is 12/24 VDC
to damage the DC control circuits of the genera- nominal. If an isolated power supply is needed, a
tor set. conductor needs to connect the B to the isolated
().
WARNING Accidental starting of the generator
set while working on it can cause severe per- REQUIRED TOOLS
sonal injury or death. Prevent accidental start- The following is a list of tools that are needed to
ing by disconnecting the starting battery cables complete this installation.
(negative [] first).
Wire stripper
Make certain the battery area has been well-ven- Crimper for installing pins
tilated before servicing the battery. Arcing can
ignite explosive hydrogen gas given off by bat- Screw driver
teries, causing severe personal injury. Arcing Drill with drill bits
can occur when a cable is removed or re-at-
tached, or when the negative () battery cable is Sawzall for cutting sheet metal
connected and a tool used to connect or discon- Measuring tools
nect the positive (+) battery cable touches the
frame or other grounded metal part of the gener- File to file down sharp edges, as needed
ator set. Always remove the negative () cable
first, and reconnect it last. Make certain hydro- INSTALLATION GUIDELINES
gen from the battery, engine fuel, and other ex-
plosive fumes are fully dissipated. This is espe-
Power
cially important if the battery has been con- If mounted within 500 feet (152.4 meters) of the
nected to a battery charger. generator set starting batteries, the HMI can be
powered from the starting batteries. If mounted
PARTS TO BE SUPPLIED BY THE more than 500 feet from the generator set, an iso-
CUSTOMER lated 12 or 24 VDC power supply is required to pow-
er the display because of the wire type required.
Wiring and Terminal Block
Cabinet Installations
Customers need to supply wiring to connect the re-
mote HMI to the controller or the separate power The HMI is rated for NEMA 1 (IP10).
supply. The wire size required depends upon the
distance between the two connections. 16 AWG Mounting
(1.31mm2) is the largest wire that can can be The HMI can be mounted a total of 4000 feet
brought into the HMI socket contact pins. If a larger (1219.2 meters) (total cable length) from the con-
wire is required, a terminal block must be used to troll.
convert the wire size from the run wire to the wire
size that fits the HMIs connectors. TABLE 1. WIRE TYPES
Maximum Mounting Dis-
A 5-pin connector will also be needed for connect- B+ and GND Wiring tance From the Generator
ing to TB15 on the HMI. Set in Feet (Meters)

Heater for Cold Environment 14 AWG (2.08mm2) 500 (152.4)

16 AWG (1.31mm2) 200 (61)
The operating temperature for the control panel is
4 ~ 158 _F (20 ~ 70 _C). If the environment that 18 AWG (0.823mm2) 100 (30.5)

Copyright 2016 Cummins Inc. Page 2 of 10 A041J096 (Issue 3)

HMI Connections This connector is oriented the same way it is ori-
ented in Figure 4.
Before the installation, become familiar with the
HMI connectors called out in Figure 4. TABLE 2. J28 PIN ASSIGNMENTS
FUNCTION /
PIN DESCRIPTION
CONNECTS TO
J28-1 Fused B+ B+ supply to HMI
J28-2 N/A
J28 J28-3 B+ Return Return / GND to HMI
J28-4 N/A

TB15 TB15 Connections

(In the control board)

J29
TB15
1
B B
2
B+ B+
3
FIGURE 4. HMI CONNECTIONS RS-485+
4
RS-485
J28 Connections 5 F2
BI_DIR WAKEUP
J28 is used for power connections. RXEF025
CON1X5
(In the control board) MOLEX_39870_0505

J28 FIGURE 7. TB15 WIRING

B+
1 F1 1
B1+
2
B2+ RTEF190
3
B1
4
B2 5

CON2X2
FIGURE 8. TB15 PINS
AMP_1_770174_0
B TABLE 3. TB15 PIN ASSIGNMENTS
FUNCTION /
PIN DESCRIPTION
FIGURE 5. J28 WIRING CONNECTS TO
TB15-1 RS-485 Shield Network Shield
2 1 TB15-2 N/A
TB15-3 RS-485 Data Network Data A
A/Modbus
TB15-4 RS-485 Data Network Data B
4 3 B/Modbus

FIGURE 6. J28 PINS TB15-5 System Wakeup

Copyright 2016 Cummins Inc. Page 3 of 10 A041J096 (Issue 3)

J29 Connections INSTALLATION

1. Make sure the generator set is shut down and

11 15
disabled.

6 a. Place the generator set control in the Off

10 mode.

5 b. Turn off and disconnect the battery char-

1 ger (if equipped).
FIGURE 9. J29 PINS c. Disconnect the negative () cable from the
battery to prevent accidental starting.
This connector is oriented the same way it is ori-
ented in Figure 4. WARNING Ignition of explosive battery
gases can cause severe personal injury. Do
TABLE 4. J29 PIN ASSIGNMENTS not smoke or cause any spark, arc, or flame
FUNCTION / while servicing batteries.
PIN DESCRIPTION
CONNECTS TO
J29-1 PCC Net A (+) Network Data A 2. Mark and cut out an area for mounting the con-
J29-2 PCC Net B () Network Data B trol panel, using the template provided in Fig-
ure 14. Drill holes for securing the control pan-
J29-3 System Wakeup
el.
J29-4 Not available on
remote HMI 3. Mount the control panel and secure it with eight
J29-5 B+ Return M4 x 0.7 x 10mm pan head machine screws
J29-6 Remote Start On remote HMI, this is and #10 split lock washers.
controlled by Remote
Start buttons and con- 4. Depending upon the distance from the genera-
nected to PCC Re- tor set, complete the wiring appropriate for your
mote Start pin. installation.
J29-7 N/A Less than 200 feet (61 meters) go to
J29-8 N/A step 5
J29-9 External Lamp A ground signal is Between 200 feet (61 meters) and 500
Driver available on pressing feet (152.4 meters) go to step 6.
the Lamp Test button.
J29-10 Fault Reset A ground signal is More than 500 feet (152.4 meters) go
available on pressing to step 7.
Reset.
J29-11 N/A 5. If the HMI is installed less than 200 feet (61 me-
ters) from the generator set, complete the wir-
J29-12 N/A
ing from the HMI to the control on the generator
J29-13 N/A set.
J29-14 N/A
a. Install socket contact pins on the ends of
J29-15 N/A
the wires that will be installed on the J28
and J29 connectors.
Low side driver output ratings:
250mA b. Install the wires with the contact pins in the
appropriate locations on the J28 and J29
1A Inrush connectors (see Figure 13).
30 VDC
c. Connect the other ends of the wires to the
100A Off State Leakage control base board (see Figure 13).

Copyright 2016 Cummins Inc. Page 4 of 10 A041J096 (Issue 3)

 Remote HMI Terminal Block
J29-6
Pilot Relay
J29-9
(Optional) Remote HMI Panel Lamp
J29-10
J28-1
J28-3
Short 16 AWG (1.31mm2) 14 AWG (2.08mm2) or Larger
FIGURE 10. HMI CONNECTIONS WITH TERMINAL BLOCK
6. If the HMI is installed more than 200 feet (61
meters) from the generator set, a terminal
block must be installed (see Figure 10).
a. Install a terminal block near the remote
HMI.
b. Cut 16 AWG (1.31mm2) wire of the ap-
propriate length for the connections be-
tween the HMI and the terminal block.
c. Install socket contact pins on the ends of
the wires that will be installed on the J28
and J29 connectors.
d. Install the wires with the contact pins in the
appropriate locations on the J28 and J29
connectors (see Figure 13).
e. Connect the other ends of the wires to the
terminal block.
f. Install wires of the appropriate size (see
Table 1) from the terminal block to the con-
trol base board (see Figure 13).
7. If the HMI is installed more than 500 feet from
the generator set, an isolated power supply
must be installed (see Figure 11).
a. Install a terminal block near the remote
HMI.
b. Cut 16 AWG (1.31mm2) wire of the ap-
propriate length for the connections be-
Copyright 2016 Cummins Inc. Page 5 of 10
Control Base Board
At the Generator Set
Remote Start (Wake-Up)
TB1-11
Customer Fused B+
TB1-5
B+ Return
TB1-10
Fault Reset (Wake-Up)
TB8-5
B+ Return
TB1-10
tween the HMI and the terminal block for
the J29 connector and pin 3 on the J28
connector.
c. Install socket contact pins on the ends of
all wires that will be installed on the J28
and J29 connectors.
d. Install the wires with the contact pins in the
appropriate locations on the J28 and J29
connectors (see Figure 13).
e. Install wires of the appropriate size (see
Table 1) from the terminal block to the con-
trol base board (see Figure 13) for the J29
and J28-3 connections. Connect J28-3 to
TB1-10.
f. Use 16 AWG (1.31mm2) wire, connect wir-
ing from the J28-3 to Iso() and J28-1 to
Iso(+) on the isolated power supply.
8. Plug the J28 connector into the HMI and apply
power to the HMI through the J28 connector.
9. With J28 connected and J29 disconnected, ac-
cess the Cummins Power Generation InCal
website (http://www.cumminspower.com) and
download the latest InCal calibration file for
your HMI.
You must update the remote HMI cal-
libration with the same part number as
the local HMI!
10. Plug the J29 connector into the HMI.
A041J096 (Issue 3)
 When a remote HMI is installed that requires its own power supply, the remote power supply MUST
be a floating power supply.
PCC Remote HMI

TB1-10 Connect with J28-3

() (Power )

J28-1
(Power +)
Internal
Ground

PCC Net PCC Net

A (+) A (+)

PCC Net PCC Net

B () B ()

Shield Supply Supply +

Floating Power Supply

No Ground (Do not
create a ground loop.)

FIGURE 11. REMOTE WIRING DIAGRAM FOR ISOLATED POWER SUPPLY

OPERATION These two buttons are not available because an op-

Differences Between a Remote HMI and a
Local HMI
The Manual Start and Auto buttons that are avail-
able on a local HMI, such as the one shown in Fig-
ure 12, are not available on a remote HMI.
erator, working at a remote location, may not be
aware of events that might be transpiring at the gen-
erator set. For example, someone performing ser-
vice procedures would not want the operator at the
remote location to suddenly start the generator set.
The Manual Start and Auto status is announced on
the remote HMI.
Pressing the Remote Start or Remote Stop but-
tons does not automatically mean that the control
will perform these functions. For example, when
the Remote Start button is pressed, a signal is sent
to the local control announcing its intention to start
the generator set. The control on the generator set
then determines if conditions are right to actually
start the unit.

FIGURE 12. LOCAL HMI320 CONTROL PANEL

Copyright 2016 Cummins Inc. Page 6 of 10 A041J096 (Issue 3)

 POWER COMMAND 1.1/1.2/2.2/2.3
CUSTOMER CONNECTIONS
PCCNet must be
removed for the PC
tool to work.

NOTE: REMOTE HMI220 WILL NOT WORK WITH THE 3.3 CONTROL.
REMOTE HMI320 WILL WORK WITH THE 2.2/2.3/3.3 CONTROLS.
REMOTE HMI320 WILL NOT WORK WITH THE 1.1/1.2 CONTROLS.

No. 630-3440 Sheet 7

Rev. L Modified

FIGURE 13. CUSTOMER CONNECTIONS

(SHEET 1 OF 2)

Copyright 2016 Cummins Inc. Page 7 of 10 A041J096 (Issue 3)

 6303440
Rev. K, Sheet 8

FIGURE 13. CUSTOMER CONNECTIONS (SHEET 2 OF 2)

Copyright 2016 Cummins Inc. Page 8 of 10 A041J096 (Issue 3)

 R7

6mm 276mm

Eight 4.2mm Holes

220.8mm

212mm

NOTE: Not all printers produce accurate copies of drawings.

If you use this drawing as a template, be sure to
check the dimensions before cutting or drilling.

110.4mm

4.3mm

142.3mm
288mm
FIGURE 14. HMI CUTOUT TEMPLATE

Copyright 2016 Cummins Inc. Page 9 of 10 A041J096 (Issue 3)

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Copyright 2016 Cummins Inc. Page 10 of 10 A041J096 (Issue 3)