Page 1 of 10 E2012 Cummins Power Generation, Inc. All rights reserved.

A041J096 (Issue 1)
3-2012
Instruction Sheet
Installation Instructions for Remote Panel Kits A041J582 (HMI220)
and A041J589 (HMI320)
GENERAL INFORMATION
These instructions provide the procedure for instal-
ling a remote control panel.
FIGURE 1. REMOTE HMI220 CONTROL PANEL
FIGURE 2. REMOTE HMI320 CONTROL PANEL
Verify that the following items are included in the kit.
TABLE 1. KIT PARTS
Item Description Qty
1 Display Panel 1
2 Plug Connector (J28) 1
3 Plug Connector (J29) 1
4 Socket Contact Pins 19
J29 Connector
J28 Connector
Display
Panel
Socket Contact Pin
FIGURE 3. KIT COMPONENTS
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.
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A041J096 (Issue 1)
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. 16 AWG
(1.31mm
2
) 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 HMIs connectors.
A 5-pin connector will also be needed for connect-
ing to TB15 on the HMI.
Heater for Cold Environment
The operating temperature for the control panel is
4 ~ 158 _F (20 ~ 70 _C). If the environment that
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
B+ and GND Wiring
Maximum Mounting Dis-
tance From the Generator
Set in Feet (Meters)
14 AWG (2.08mm
2
) 500 (152.4)
16 AWG (1.31mm
2
) 200 (61)
18 AWG (0.823mm
2
) 100 (30.5)
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A041J096 (Issue 1)
HMI Connections
Before the installation, become familiar with the
HMI connectors called out in Figure 4.
J29
TB15
J28
FIGURE 4. HMI CONNECTIONS
J28 Connections
J28 is used for power connections.
J28
RTEF190
B+
1
B1+
2
B2+
3
B1
4
B2
CON2X2
AMP_1_770174_0
F1
B
(In the control board)
FIGURE 5. J28 WIRING
4
2
1
3
FIGURE 6. J28 PINS
This connector is oriented the same way it is ori-
ented in Figure 4.
TABLE 2. J28 PIN ASSIGNMENTS
PIN DESCRIPTION
FUNCTION /
CONNECTS TO
J28-1 Fused B+ B+ supply to HMI
J28-2 N/A
J28-3 B+ Return Return / GND to HMI
J28-4 N/A
TB15 Connections
TB15
RXEF025
B
1
B
B+
2
B+
3
RS-485+
4
RS-485
5
BI_DIR WAKEUP
CON1X5
MOLEX_39870_0505
F2
(In the control board)
FIGURE 7. TB15 WIRING
1
5
FIGURE 8. TB15 PINS
TABLE 3. TB15 PIN ASSIGNMENTS
PIN DESCRIPTION
FUNCTION /
CONNECTS TO
TB15-1 RS-485 Shield Network Shield
TB15-2 N/A
TB15-3 RS-485 Data
A/Modbus
Network Data A
TB15-4 RS-485 Data
B/Modbus
Network Data B
TB15-5 System Wakeup
Page 4 of 10
A041J096 (Issue 1)
J29 Connections
1
6
11
15
10
5
FIGURE 9. J29 PINS
This connector is oriented the same way it is ori-
ented in Figure 4.
TABLE 4. J29 PIN ASSIGNMENTS
PIN DESCRIPTION
FUNCTION /
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
Driver
A ground signal is
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
Low side driver output ratings:
250mA
1A Inrush
30 VDC
100A Off State Leakage
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.
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).
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A041J096 (Issue 1)
Short 16 AWG (1.31mm
2
)
Terminal Block
Remote HMI
J29-6
J29-9
J29-10
Control Base Board
At the Generator Set
TB1-11
TB1-5
TB1-10
Remote Start (Wake-Up)
Customer Fused B+
B+ Return
14 AWG (2.08mm
2
) or Larger
TB8-5
Pilot Relay
Fault Reset (Wake-Up)
J28-1
J28-3
(Optional) Remote HMI Panel Lamp
TB1-10
B+ Return
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 (1.31mm
2
) 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 (1.31mm
2
) wire of the ap-
propriate length for the connections be-
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 (1.31mm
2
) 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 software!
10. Plug the J29 connector into the HMI.
Page 6 of 10
A041J096 (Issue 1)
PCC Net
A (+)
PCC Net
B ()
TB1-10
()
Remote HMI
Floating Power Supply
No Ground (Do not
create a ground loop.)
Supply Supply +
PCC Net
A (+)
PCC Net
B ()
J28-1
(Power +)
J28-3
(Power )
When a remote HMI is installed that requires its own power supply, the remote power supply MUST
be a floating power supply.
PCC
Connect with
Shield
Internal
Ground
FIGURE 11. REMOTE WIRING DIAGRAM FOR ISOLATED POWER SUPPLY
OPERATION
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.
FIGURE 12. LOCAL HMI320 CONTROL PANEL
These two buttons are not available because an op-
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.
A041J096 (Issue 1)
Page 7 of 10
No. 630-3440 Sheet 7
Rev. L Modified
POWER COMMAND 1.1/1.2/2.2/2.3
CUSTOMER CONNECTIONS
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.
PCCNet must be
removed for the PC
tool to work.
FIGURE 13. CUSTOMER CONNECTIONS
(SHEET 1 OF 2)
A041J096_Issue 1)
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6303440
Rev. K, Sheet 8

FIGURE 13. CUSTOMER CONNECTIONS (SHEET 2 OF 2)
A041J096 (Issue 1)
Page 9 of 10
142.3mm
276mm
212mm
110.4mm
288mm
Eight 4.2mm Holes
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.
220.8mm
6mm
4.3mm
R7
FIGURE 14. HMI CUTOUT TEMPLATE
A041J096_Issue 1)
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