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 1 Display Panel 1
instal-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.
WARNING Incorrect installation can result in
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-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.
CAUTION Always disconnect a battery char-
ger 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 genera-tor 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 battery. Arcing can
ignite explosive hydrogen gas given off by bat-
teries, causing severe personal injury. Arcing
can occur when a cable is removed or re-at-
tached, or when the negative (−) battery cable is
connected and a tool used to connect or discon-
nect the positive (+) battery cable touches the
frame or other grounded metal part of the gener-
ator set. Always remove the negative (−) cable
first, and reconnect it last. Make certain hydro-
gen from the battery, engine fuel, and other ex-
plosive fumes are fully dissipated. This is espe-
cially important if the battery has been con-
nected to a battery charger.
PARTS TO BE SUPPLIED BY THE
CUSTOMER
Wiring and Terminal Block
Customers need to supply wiring to connect the
re-mote HMI to the controller or the separate
power supply. The wire size required depends
upon the distance between the two connections.
2
16 AWG (1.31mm ) is the largest wire that can
can be brought into the HMI socket contact pins.
If a larger wire is required, a terminal block must
be used to convert the wire size from the run wire
to the wire size that fits the HMI’s connectors.
the HMI will be located in will be below −4 _F,
(−20 _C), install an HMI heater (kit A026J556
includes In-struction Sheet A028X284).
Isolated Remote Power Supply
If the voltage drop in the wires is too excessive,
due to the wire losses, an isolated remote power
supply will need to be installed. Voltage range is
12/24 VDC nominal. If an isolated power supply is
needed, a conductor needs to connect the B− to
the isolated (−).
REQUIRED TOOLS
The following is a list of tools that are needed to
complete this installation.
 Wire stripper
 Crimper for installing pins
 Screw driver
 Drill with drill bits
 Sawzall for cutting sheet metal
 Measuring tools
 File to file down sharp edges, as needed
INSTALLATION GUIDELINES
Power
If mounted within 500 feet (152.4 meters) of the
generator set starting batteries, the HMI can be
powered from the starting batteries. If mounted
more than 500 feet from the generator set, an iso-
lated 12 or 24 VDC power supply is required to pow-
er the display because of the wire type required.
Cabinet Installations
The HMI is rated for NEMA 1 (IP10).
Mounting
The HMI can be mounted a total of 4000 feet
(1219.2 meters) (total cable length) from the con-
troll.
TABLE 1. WIRE TYPES

A 5-pin connector will also be needed for Maximum Mounting Dis-

B+ and GND Wiring tance From the Generator
connect-ing to TB15 on the HMI.
Set in Feet (Meters)
Heater for Cold Environment
2
14 AWG (2.08mm ) 500 (152.4)
The operating temperature for the control panel is 2
−4 ~ 158 _F (−20 ~ 70 _C). If the environment that 16 AWG (1.31mm ) 200 (61)
2
18 AWG (0.823mm ) 100 (30.5)

A041J096 (Issue 3)
Copyright  2016 Cummins Inc. Page 2 of 10
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
J28-2 N/A

J28-3 B+ Return Return / GND to HMI

TB15
J28-4 N/A

TB15 Connections
J29

(In the control board)

TB15
FIGURE 4. HMI CONNECTIONS
1
J28 Connections B−
J28 is used for power connections. B− 2

B+
B+ 3

RS-485+ 4

RS-485−
5 F2
BI_DIR WAKEUP
RXEF025
CON1X5
(In the control board) MOLEX_39870_0505

J28 FIGURE 7. TB15 WIRING

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

CON2X2
AMP_1_770174_0 FIGURE 8. TB15 PINS

TABLE 3. TB15 PIN ASSIGNMENTS

B−
PIN DESCRIPTION FUNCTION /
FIGURE 5. J28 WIRING

2
 CONNECTS TO
TB15-1 RS-485 Shield Network Shield
TB15-2 N/A
4
TB15-3 RS-485 Data Network Data A
FIGURE 6. J28 PINS A/Modbus
TB15-4 RS-485 Data Network Data B
B/Modbus
TB15-5 System Wakeup

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

J29 Connections

Low side driver output ratings:

11
 250mA

6  1A Inrush
 30 VDC
 100A Off State Leakage
1

FIGURE 9. J29 PINS

This connector is oriented the same way it is ori-

ented in Figure 4.

TABLE 4. J29 PIN ASSIGNMENTS

FUNCTION /
PIN DESCRIPTION
CONNECTS TO
J29-1 PCC Net A (+) Network Data A

J29-2 PCC Net B (−) Network Data B

J29-3 System Wakeup

J29-4 Not available on

remote HMI

J29-5 B+ Return

J29-6 Remote Start On remote HMI, this is

controlled by Remote
Start buttons and con-
nected to PCC Re-
mote Start pin.

J29-7 N/A

J29-8 N/A

J29-9 External Lamp A ground signal is

Driver available on pressing
the Lamp Test button.

J29-10 Fault Reset A ground signal is

available on pressing
Reset.

J29-11 N/A

J29-12 N/A

J29-13 N/A

J29-14 N/A

J29-15 N/A
 INSTALLATION
1. Make sure the generator set is shut down and
disabled.
a. Place the generator set control in the Off
mode.
b. Turn off and disconnect the battery char-
ger (if equipped).
c. Disconnect the negative (−) cable from the
battery to prevent accidental starting.
WARNING Ignition of explosive battery
gases can cause severe personal injury. Do
not smoke or cause any spark, arc, or flame
while servicing batteries.
2. Mark and cut out an area for mounting the con-
trol panel, using the template provided in Fig-ure
14. Drill holes for securing the control pan-el.
3. Mount the control panel and secure it with eight
M4 x 0.7 x 10mm pan head machine screws and
#10 split lock washers.
Copyright  2016 Cummins Inc.
4. Depending upon the distance from the
genera-tor set, complete the wiring appropriate
for your installation.
 Less than 200 feet (61 meters) − go to
step 5
 Between 200 feet (61 meters) and 500
feet (152.4 meters) − go to step 6.
 More than 500 feet (152.4 meters) − go
to step 7.
5. If the HMI is installed less than 200 feet (61
me-ters) from the generator set, complete the
wir-ing from the HMI to the control on the
generator set.
a. Install socket contact pins on the ends of
the wires that will be installed on the J28
and J29 connectors.
b. Install the wires with the contact pins in
the appropriate locations on the J28 and J29
connectors (see Figure 13).
c. Connect the other ends of the wires to
the control base board (see Figure 13).
A041J096 (Issue 3)
Page 4 of 10
 Remote HMI Terminal Block Control Base Board
At the Generator Set
Remote Start (Wake-Up)
J29-6 TB1-11

Pilot Relay Customer Fused B+

TB1-5
B+ Return
J29-9 TB1-10
(Optional) Remote HMI Panel Lamp
Fault Reset (Wake-Up)
J29-10 TB8-5

J28-1
B+ Return
J28-3 TB1-10

2 2
Short 16 AWG (1.31mm ) 14 AWG (2.08mm ) or Larger
FIGURE 10. HMI CONNECTIONS WITH TERMINAL BLOCK

6. If the HMI is installed more than 200 feet (61 tween the HMI and the terminal block for
meters) from the generator set, a terminal block the J29 connector and pin 3 on the J28
must be installed (see Figure 10). connector.
a. Install a terminal block near the remote c. Install socket contact pins on the ends of
HMI. all wires that will be installed on the J28
2 and J29 connectors.
b. Cut 16 AWG (1.31mm ) wire of the ap-
d. Install the wires with the contact pins in
propriate length for the connections be-tween the
HMI and the terminal block. the appropriate locations on the J28 and J29
connectors (see Figure 13).
c. Install socket contact pins on the ends of
e. Install wires of the appropriate size (see
the wires that will be installed on the J28 and J29
Table 1) from the terminal block to the con-trol
connectors. base board (see Figure 13) for the J29 and J28-3
d. Install the wires with the contact pins in connections. Connect J28-3 to TB1-10.
the appropriate locations on the J28 and J29 2
f. Use 16 AWG (1.31mm ) wire, connect
connectors (see Figure 13). wir-ing from the J28-3 to Iso(−) and J28-1 to
e. Connect the other ends of the wires to Iso(+) on the isolated power supply.
the terminal block. 8. Plug the J28 connector into the HMI and apply
power to the HMI through the J28 connector.
f. Install wires of the appropriate size (see
Table 1) from the terminal block to the con-trol 9. With J28 connected and J29 disconnected, ac-
base board (see Figure 13). cess the Cummins Power Generation InCal website
(http://www.cumminspower.com) and download
7. If the HMI is installed more than 500 feet from the latest InCal calibration file for your HMI.
the generator set, an isolated power supply must You must update the remote HMI cal-
be installed (see Figure 11).
libration with the same part number as
a. Install a terminal block near the remote the local HMI!
HMI.
10. Plug the J29 connector into the HMI.
2
b. Cut 16 AWG (1.31mm ) wire of the ap-
propriate length for the connections be-
Copyright  2016 Cummins Inc. Page 5 of 10 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
Internal (Power +)
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

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

 630−3440
Rev. K, Sheet 8

FIGURE 13. CUSTOMER CONNECTIONS (SHEET 2 OF 2)

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