Kohler Tt1584PIM

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Kohler Power Generation PIM Installation Manual

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<ul><li><p>INSTALLATION INSTRUCTIONS</p><p>TT-1584 2/12a</p><p>Original Issue Date: 2/12</p><p>Model: 14RESA/RESAL, 20RESA/RESAL, and 48RCL</p><p>Market: Residential/Light Commercial</p><p>Subject: Programmable Interface Module (PIM) Kits GM81529-KP1-QS</p><p>Introduction</p><p>The optional Programmable Interface Module (PIM)</p><p>provides two programmable inputs and six</p><p>programmable outputs for connection to</p><p>customer-supplied equipment. The PIM operates only</p><p>with generator sets equipped with the Kohler RDC2 or</p><p>DC2 controller, including the following models:</p><p> 14RESA/RESAL</p><p> 20RESA/RESAL</p><p> 48RCL</p><p>ThePIM ismounted in aNEMA3Renclosure, which can</p><p>be installed indoors or outdoors. The PIM with</p><p>enclosure is shown in Figure 1. For outdoor installation,</p><p>use watertight conduit hubs.</p><p>ADV--8199</p><p>Figure 1 Programmable Interface Module (cover</p><p>removed for illustration)</p><p>Inputs and outputs are factory-set to theevents shown in</p><p>Figure 7. The inputs and outputs 3--6 can be changed</p><p>using a laptop computer connected to the RDC2 or DC2</p><p>controller and Kohler SiteTech software . SiteTech is</p><p>available to Kohler-authorized distributors.</p><p>A maximum of three accessory modules can be</p><p>connected to the generator set. Accessorymodules can</p><p>include one programmable interface module (PIM), one</p><p>Model RXT transfer switch, and/or one load control</p><p>module (LCM).</p><p>Read the entire installation procedure and compare the</p><p>kit parts with the parts list at the end of this publication</p><p>before beginning installation. Perform the steps in the</p><p>order shown.</p><p>OnCue Remote Monitoring and</p><p>Control</p><p>The Kohler OnCue Generator Management System</p><p>can be used to monitor the PIM inputs and outputs.</p><p>OnCue can also be used to remotely control PIMoutputs</p><p>3 through 6. For example, connect output 3 to the storm</p><p>shutters on your vacation home and label it Storm</p><p>Shutters in the Power Chain view in OnCue. When bad</p><p>weather is forecast, you can use your computer to close</p><p>the storm shutters from a remote location.</p><p>The OnCue kit is available from Kohler-authorized</p><p>distributors and dealers. See TP-6796, OnCue</p><p>Software Operation Manual, for instructions to connect</p><p>the generator set to the Internet and use OnCue on a</p><p>personal computer.</p></li><li><p>2 TT-1584 2/12a</p><p>Safety Precautions</p><p>Observe the following safety precautionswhile installing</p><p>the kit.</p><p>Accidental starting.Can cause severe injury or death.</p><p>Disconnect the battery cables beforeworking on the generator set.</p><p>Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.</p><p>WARNING</p><p>Disabling the generator set. Accidental starting can</p><p>cause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative</p><p>(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.</p><p>Hazardous voltage.Will cause severe injury or death.</p><p>Disconnect all power sources beforeopening the enclosure.</p><p>DANGER</p><p>Installation Procedure</p><p>1. Press the OFF button on the generator sets</p><p>RDC2/DC2 controller.</p><p>2. Disconnect the utility power to the generator set.</p><p>3. Disconnect the generator set engine starting</p><p>battery(ies), negative (--) lead first.</p><p>4. Remove the PIM enclosure cover. Cover the PIM</p><p>circuit board to protect it from metal chips and</p><p>debris.</p><p>5. Cut holes in the PIMenclosure for the generator set</p><p>communication leads and input and output leads.</p><p>For outdoor installation, use weather-tight conduit</p><p>connectors.</p><p>Note: Use separate conduit for the low-voltage</p><p>communication leads to the generator set</p><p>controller. To ensure separation of circuits</p><p>per NEC requirements, route low-voltage</p><p>AC and DC wiring separately from</p><p>line-voltage wiring.</p><p>6. Mount the PIM enclosure to a wall. See the</p><p>dimension drawing in Figure 26 for the mounting</p><p>hole size and locations.</p><p>Note: The mounting holes have gaskets to seal</p><p>out moisture. Use washers with the</p><p>mounting screws to protect the gaskets.</p><p>7. Connect A, B, PWR, andCOMon connector P10 to</p><p>the corresponding generator set connectors. See</p><p>Figure 2 through Figure 5. Use Belden #9402</p><p>(4-conductor) or equivalent 20 AWG shielded,</p><p>twisted-pair cable. The maximum cable length is</p><p>61 m (200 ft.).</p><p>Note: If a longer cable run is required, or if</p><p>additional accessories such as a transfer</p><p>switch or a load control module (LCM) are</p><p>used, seeCommunication Connectionswith</p><p>Additional Accessories on page 5.</p><p>1</p><p>ADV-7876</p><p>1. Customer connection terminal block</p><p>Figure 2 14/20RESA Terminal Block Location</p></li><li><p>TT-1584 2/12a 3</p><p>1</p><p>tp6809</p><p>1. Customer connection terminal block</p><p>Note: Access panel removed for illustration.</p><p>Figure 3 Model 48RCL Terminal Block Location</p><p>5</p><p>1. TB4, relay 3 and relay 4 connections</p><p>2. P10, connection to generator set3. TB2, input 1 and input 2 connections</p><p>4. LED1, online</p><p>5. TB3, relay 1 and relay 2 connections6. TB5, relay 5 and relay 6 connections</p><p>7. LED2, power</p><p>6</p><p>ADV--8199</p><p>1</p><p>3</p><p>2</p><p>4</p><p>7</p><p>Figure 4 PIM Circuit Board Connections and LEDs</p><p>Generator Set</p><p>Connect one end of each cable shieldto GROUND at the generator set.</p><p>Leave one end of each cable shielddisconnected at the last device.</p><p>PIM1</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable</p><p>GND</p><p>A</p><p>B</p><p>COM</p><p>PWR</p><p>3</p><p>4</p><p>TB1</p><p>NOTE: See Figure 2 or Figure 3 for the terminal block</p><p>location on the generator set. Check the decal on thegenerator set for terminal block connections.</p><p>RBUS</p><p>12 VDC</p><p>Figure 5 PIM Communication Connections to Generator Set</p></li><li><p>4 TT-1584 2/12a</p><p>8. Connect customer equipment to inputs 1 and 2 on</p><p>TB2 on the PIM circuit board. See Figure 6 for the</p><p>cable size. See the wiring diagram in Figure 27.</p><p>9. Connect customer equipment to output relays 1</p><p>through 6 on TB3, TB4, and TB5. Note the</p><p>factory-default output settings shown in Figure 7.</p><p>Refer to the wiring diagram in Figure 27 and</p><p>connect to each relays normally open or normally</p><p>closed contacts as required.</p><p>10. Turn the locking tab out so that the enclosure door</p><p>can be secured with a padlock.</p><p>11. Install the door and secure with the door screw.</p><p>Lock the enclosure door with a padlock to prevent</p><p>unauthorized entry.</p><p>12. Reconnect the generator set engine starting</p><p>battery, negative (--) lead last.</p><p>13. Reconnect utility power to the generator set.</p><p>14. Press the AUTO button on the generator set</p><p>controller.</p><p>PIM Connection Specifications</p><p>Input Rating 10 mA @ 12 VDC dry contact</p><p>Output Relay Rating 10 A @ 120 VAC</p><p>Wire Size 12--24 AWG</p><p>Screw Torque 7 in. lbs</p><p>Figure 6 Input/Output Connection Specifications</p><p>15. Note the factory-assigned functions for the digital</p><p>outputs shown in Figure 7. Use a personal</p><p>computer connected to theRDC2or DC2 controller</p><p>and Kohler SiteTech software to change the</p><p>input and output functions, if necessary. Available</p><p>input and output functions are listed in Figure 16</p><p>and Figure 17. See TP-6701, SiteTech Software</p><p>Operation Manual, for instructions.</p><p>PIM Connection SiteTech Name</p><p>DefaultSetting(Event)</p><p>Input 1 TB2 IN1 Digital Input B1 None</p><p>Input 2 TB2 IN2 Digital Input B2 None</p><p>Output 1 TB3</p><p>Relay 1</p><p>Digital Output B1 Generator</p><p>Running</p><p>Output 2 TB3</p><p>Relay 2</p><p>Digital Output B2 Common Fault</p><p>Output 3 TB4</p><p>Relay 3</p><p>Digital Output B3 Low Battery</p><p>Voltage</p><p>Output 4 TB4</p><p>Relay 4</p><p>Digital Output B4 Not in Auto</p><p>Output 5 TB5</p><p>Relay 5</p><p>Digital Output B5 Cooldown</p><p>Output 6 TB5</p><p>Relay 6</p><p>Digital Output B6 Normal Source</p><p>Failure</p><p>Figure 7 Inputs and Outputs</p></li><li><p>TT-1584 2/12a 5</p><p>Communication Connections with</p><p>Additional Accessories</p><p>See Figure 9 through Figure 14 for connection options</p><p>with up to three accessory modules. Accessory</p><p>modules can include one Model RXT transfer switch,</p><p>one programmable interface module (PIM), and/or one</p><p>load control module (LCM).</p><p>See Figure 8 for the maximum total cable length with 1,</p><p>2, or 3 accessory modules per cable run.</p><p> Use Belden #9402 (4-conductor) or equivalent</p><p>20 AWG shielded, twisted-pair cable. Note the shield</p><p>connections shown in Figure 9.</p><p> If longer cable runs are required, #12--14 AWG wire</p><p>can be used for the COMand PWR connections. The</p><p>maximum total cable length is the value shown for</p><p>#12 or #14 AWGwire in Figure 8. The 20 AWG cable</p><p>used for communication connections A and B (only)</p><p>can be as long as 152 m (500 ft.).</p><p>Cable (TB1--PWR and COM)</p><p>Maximum length per run, meters (ft.)</p><p>Number of Modules (ATS, PIM, and LCM) per Run</p><p>1 Module 2 Modules 3 Modules</p><p>Belden #9402 or equivalent 20AWG 61 (200) 31 (100) 21 (67)</p><p>14 AWG 152 (500) 152 (500) 122 (400)</p><p>12 AWG 152 (500) 152 (500) 152 (500)</p><p>Figure 8 Total Cable Lengths with Accessory Modules Connected</p><p>PIM</p><p>LCM</p><p>Generator Set</p><p>COM</p><p>PWR</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>B</p><p>A</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>Connect one end of each cable shieldto GROUND at the generator set.</p><p>Leave one end of each cable shield disconnected at the last device.</p><p>RXT1</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>Connect shields togetheras shown.</p><p>1. Communication cable Belden #9402 or equivalent</p><p>20 AWG shielded, twisted-pair cable</p><p>GND</p><p>A</p><p>B</p><p>COM</p><p>PWR</p><p>3</p><p>4</p><p>TB1</p><p>NOTES:</p><p> See thegeneratorset InstallationManual for terminal</p><p>block location on generator set. Check the decal on</p><p>the generator set for terminal block connections.</p><p> See Figure 8 for maximum total cable length per run</p><p>(1 run shown)</p><p> Current transformer must be installed on theemergency source leads.</p><p>RBUS</p><p>12 VDCCOM</p><p>PWR</p><p>A</p><p>B</p><p>Figure 9 Communication Connection Details with Model RXT Transfer Switch</p></li><li><p>6 TT-1584 2/12a</p><p>LCM</p><p>Generator Set</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>Connect one end of each cable shieldto GROUND at the generator set.</p><p>Leave one end of each cable shield disconnected at the last device.</p><p>PIM1</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>Connect shields togetheras shown.</p><p>1. Communication cable Belden #9402 or equivalent 20 AWG</p><p>shielded, twisted-pair cable2. Engine start leads 3 and 4. See the ATS manual for cable</p><p>size specifications.</p><p>GND</p><p>A</p><p>B</p><p>COM</p><p>PWR</p><p>3</p><p>4</p><p>TB1</p><p>NOTES:</p><p> See thegeneratorset InstallationManual for terminal</p><p>block location on generator set. Check the decal on</p><p>the generator set for terminal block connections.</p><p> See Figure 8 for maximum total cable length per run</p><p>(1 run shown)</p><p> Current transformer must be installed on theemergency source leads.</p><p>RBUS</p><p>12 VDCCOM</p><p>PWR</p><p>A</p><p>B</p><p>ATSModels RDTor RSB</p><p>2</p><p>2 4</p><p>3</p><p>Figure 10 Connection Details with Model RDT or RSB Transfer Switch</p></li><li><p>TT-1584 2/12a 7</p><p>NOTES:</p><p> See the generator set Installation Manual for terminal block location on</p><p>generator set. Check the decal on the generator set for terminal block</p><p>connections.</p><p> See Figure 8 for maximum total cable length per run (3 runs with 1module</p><p>each shown).</p><p> See Figure 9 for communication connection detail (A and B, PWR andCOM).</p><p> Use splices or wire nuts to collect multiple leads for connection to the</p><p>generator set terminal block. See Figure 12.</p><p>1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803</p><p>PIM</p><p>LCM</p><p>RXT ATS</p><p>Generator Set</p><p>TB1</p><p>1</p><p>1</p><p>1</p><p>Figure 11 Accessory Module Connections, Star Configuration (three cable runs with one module each)</p><p>1</p><p>tp6803</p><p>1. Splice</p><p>Generator Set</p><p>Generator Set Terminal Block TB1.See the generator set Installation Manual for location.Check the decal on the generator set for terminal block connections.</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>Connect all of the shield leads on thisend to GROUND at the generator set.</p><p>COM</p><p>PWR</p><p>B</p><p>A</p><p>To GROUND</p><p>9402 CABLE</p><p>9402 CABLE</p><p>A</p><p>B</p><p>COM</p><p>PWR</p><p>3</p><p>4</p><p>TB1</p><p>RBUS</p><p>12 VDC</p><p>GND</p><p>Figure 12 Multiple Connections to the Generator Set</p></li><li><p>8 TT-1584 2/12a</p><p>1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803</p><p>PIM</p><p>LCM</p><p>RXT ATS1</p><p>1</p><p>1</p><p>Generator Set</p><p>TB1</p><p>NOTES:</p><p> See the generator set Installation Manual for terminal block</p><p>locationongenerator set. Check thedecalon thegenerator set for</p><p>terminal block connections.</p><p> See Figure 8 for maximum total cable length with12 or 14 AWG wire.</p><p> See Figure 9 for communication connection (A and B, PWR andCOM) detail. Connect the cable shield to ground at the generator</p><p>set.</p><p>Figure 13 Accessory Module Connections (two cable runs with one and two modules shown)</p><p>1. Belden #9402 or equivalent, 20 AWG shielded cable (use one pair); or</p><p>Belden #8762 or equivalent 20 AWG shielded cable2. 12--14 AWG wire</p><p>tp6803</p><p>PIM</p><p>LCM</p><p>RXT ATS</p><p>1</p><p>1</p><p>1</p><p>Generator Set A and BPWRCOM 2</p><p>2</p><p>22</p><p>2</p><p>2</p><p>A and B</p><p>A and B</p><p>A and B</p><p>PWRCOM</p><p>PWRCOM</p><p>PWRCOM</p><p>NOTES:</p><p> See the generator set Installation Manual for terminal block location on</p><p>generator set. Check the decal on the generator set for terminal block</p><p>connections.</p><p> SeeFigure 8 formaximum total cable length with 12 or 14 AWGwire. (1</p><p>run with 3 modules shown).</p><p> See Figure 9 for communication connection (A and B) detail. Connectthe cable shield to ground at the generator set.</p><p>Figure 14 Accessory Module Connections with 12--14 AWG Power Leads (one cable run with three modules</p><p>shown)</p></li><li><p>TT-1584 2/12a 9</p><p>PIM Inputs and Outputs</p><p>Connect customer-supplied equipment to the PIM input</p><p>and output connections. Connect to the normally open</p><p>or normally closed output contacts as required for the</p><p>application. See the wiring diagram for connection</p><p>details.</p><p>Run/Common Fault Outputs</p><p>The first two PIM outputs are factory-set to Generator</p><p>Running and Common Fault. See Figure 7. The</p><p>generator running output is activated when the</p><p>generator set is running. The common fault output is</p><p>activated on a fault.</p><p>Changing Input and Output Settings</p><p>Use a laptop computer connected to the RDC2 or DC2</p><p>controller and running Kohler SiteTech software to</p><p>change the event settings for factory-set inputs and</p><p>outputs. Be sure to select Digital Inputs B1--B2 and</p><p>Digital Outputs B1--B6 in SiteTech. See Figure 7 and</p><p>Figure 15. Digital Inputs A1--A2 and Digital Outputs</p><p>A1--A2 and B7--B12 do not apply to the PIM.</p><p>Note: SiteTech software is available to</p><p>Kohler-authorized distributors.</p><p>The available programmable input and digital output</p><p>functions are listed in Figure 16 and Figure 17. At</p><p>installation, note the input and output connections.</p><p>Then use Kohler SiteTech software to assign the</p><p>corresponding input and output functions if they are</p><p>different than the defaults shown in Figure 7.</p><p>1</p><p>tt15841. PIM Digital Input B1 settings</p><p>2. PIM Digital Output B3 settings</p><p>2</p><p>Figure 15 SiteTech Screen, Input and Output</p><p>Settings</p><p>Input Level</p><p>Auxiliary Input Shutdown</p><p>Auxiliary Input Warning</p><p>Battery Charger Fault Warning</p><p>Chicago Code Active Notice</p><p>Engine Fuel Level Critically High Warning</p><p>Engine Fuel Level High Warning</p><p>Engine Fuel Level Low Warning</p><p>Engine Fuel Level Low Shutdown</p><p>Engine Oil Level Low Warning</p><p>Engine Oil Level Low Shutdown</p><p>Fuel Pressure Low Warning</p><p>Fuel Tank Leak Shutdown</p><p>Fuel Tank Leak Warning</p><p>Ground Fault Input Warning</p><p>Remote Reset Status</p><p>* Some inputs do not apply to all models.</p><p>Figure 16 Programmable Inputs</p></li><li><p>10 TT-1584 2/12a</p><p>Digital Output Level * 14/20 48</p><p>AC Sensing Lost W </p><p>AC Sensing Lost S </p><p>Alternator Protection S NA NA</p><p>Always Off N </p><p>Always On N </p><p>ATS Fail To Transfer W </p><p>ATS Fail To Transfer S NA NA</p><p>ATS Phase RotationMismatch (3-phase only) </p><p>W NA </p><p>Auxiliary Input W </p><p>Auxiliary Input S </p><p>Battery Charger Fault W </p><p>Battery Voltage High W </p><p>Battery Voltage Low W </p><p>Chicago Code Active N </p><p>Common Fault...</p></li></ul>