Kohler Tt1584PIM

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Kohler Power Generation PIM Installation Manual

Text of Kohler Tt1584PIM

  • INSTALLATION INSTRUCTIONS

    TT-1584 2/12a

    Original Issue Date: 2/12

    Model: 14RESA/RESAL, 20RESA/RESAL, and 48RCL

    Market: Residential/Light Commercial

    Subject: Programmable Interface Module (PIM) Kits GM81529-KP1-QS

    Introduction

    The optional Programmable Interface Module (PIM)

    provides two programmable inputs and six

    programmable outputs for connection to

    customer-supplied equipment. The PIM operates only

    with generator sets equipped with the Kohler RDC2 or

    DC2 controller, including the following models:

    14RESA/RESAL

    20RESA/RESAL

    48RCL

    ThePIM ismounted in aNEMA3Renclosure, which can

    be installed indoors or outdoors. The PIM with

    enclosure is shown in Figure 1. For outdoor installation,

    use watertight conduit hubs.

    ADV--8199

    Figure 1 Programmable Interface Module (cover

    removed for illustration)

    Inputs and outputs are factory-set to theevents shown in

    Figure 7. The inputs and outputs 3--6 can be changed

    using a laptop computer connected to the RDC2 or DC2

    controller and Kohler SiteTech software . SiteTech is

    available to Kohler-authorized distributors.

    A maximum of three accessory modules can be

    connected to the generator set. Accessorymodules can

    include one programmable interface module (PIM), one

    Model RXT transfer switch, and/or one load control

    module (LCM).

    Read the entire installation procedure and compare the

    kit parts with the parts list at the end of this publication

    before beginning installation. Perform the steps in the

    order shown.

    OnCue Remote Monitoring and

    Control

    The Kohler OnCue Generator Management System

    can be used to monitor the PIM inputs and outputs.

    OnCue can also be used to remotely control PIMoutputs

    3 through 6. For example, connect output 3 to the storm

    shutters on your vacation home and label it Storm

    Shutters in the Power Chain view in OnCue. When bad

    weather is forecast, you can use your computer to close

    the storm shutters from a remote location.

    The OnCue kit is available from Kohler-authorized

    distributors and dealers. See TP-6796, OnCue

    Software Operation Manual, for instructions to connect

    the generator set to the Internet and use OnCue on a

    personal computer.

  • 2 TT-1584 2/12a

    Safety Precautions

    Observe the following safety precautionswhile installing

    the kit.

    Accidental starting.Can cause severe injury or death.

    Disconnect the battery cables beforeworking on the generator set.

    Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

    WARNING

    Disabling the generator set. Accidental starting can

    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

    (--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.

    Hazardous voltage.Will cause severe injury or death.

    Disconnect all power sources beforeopening the enclosure.

    DANGER

    Installation Procedure

    1. Press the OFF button on the generator sets

    RDC2/DC2 controller.

    2. Disconnect the utility power to the generator set.

    3. Disconnect the generator set engine starting

    battery(ies), negative (--) lead first.

    4. Remove the PIM enclosure cover. Cover the PIM

    circuit board to protect it from metal chips and

    debris.

    5. Cut holes in the PIMenclosure for the generator set

    communication leads and input and output leads.

    For outdoor installation, use weather-tight conduit

    connectors.

    Note: Use separate conduit for the low-voltage

    communication leads to the generator set

    controller. To ensure separation of circuits

    per NEC requirements, route low-voltage

    AC and DC wiring separately from

    line-voltage wiring.

    6. Mount the PIM enclosure to a wall. See the

    dimension drawing in Figure 26 for the mounting

    hole size and locations.

    Note: The mounting holes have gaskets to seal

    out moisture. Use washers with the

    mounting screws to protect the gaskets.

    7. Connect A, B, PWR, andCOMon connector P10 to

    the corresponding generator set connectors. See

    Figure 2 through Figure 5. Use Belden #9402

    (4-conductor) or equivalent 20 AWG shielded,

    twisted-pair cable. The maximum cable length is

    61 m (200 ft.).

    Note: If a longer cable run is required, or if

    additional accessories such as a transfer

    switch or a load control module (LCM) are

    used, seeCommunication Connectionswith

    Additional Accessories on page 5.

    1

    ADV-7876

    1. Customer connection terminal block

    Figure 2 14/20RESA Terminal Block Location

  • TT-1584 2/12a 3

    1

    tp6809

    1. Customer connection terminal block

    Note: Access panel removed for illustration.

    Figure 3 Model 48RCL Terminal Block Location

    5

    1. TB4, relay 3 and relay 4 connections

    2. P10, connection to generator set3. TB2, input 1 and input 2 connections

    4. LED1, online

    5. TB3, relay 1 and relay 2 connections6. TB5, relay 5 and relay 6 connections

    7. LED2, power

    6

    ADV--8199

    1

    3

    2

    4

    7

    Figure 4 PIM Circuit Board Connections and LEDs

    Generator Set

    Connect one end of each cable shieldto GROUND at the generator set.

    Leave one end of each cable shielddisconnected at the last device.

    PIM1

    COM

    PWR

    B

    A

    1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable

    GND

    A

    B

    COM

    PWR

    3

    4

    TB1

    NOTE: See Figure 2 or Figure 3 for the terminal block

    location on the generator set. Check the decal on thegenerator set for terminal block connections.

    RBUS

    12 VDC

    Figure 5 PIM Communication Connections to Generator Set

  • 4 TT-1584 2/12a

    8. Connect customer equipment to inputs 1 and 2 on

    TB2 on the PIM circuit board. See Figure 6 for the

    cable size. See the wiring diagram in Figure 27.

    9. Connect customer equipment to output relays 1

    through 6 on TB3, TB4, and TB5. Note the

    factory-default output settings shown in Figure 7.

    Refer to the wiring diagram in Figure 27 and

    connect to each relays normally open or normally

    closed contacts as required.

    10. Turn the locking tab out so that the enclosure door

    can be secured with a padlock.

    11. Install the door and secure with the door screw.

    Lock the enclosure door with a padlock to prevent

    unauthorized entry.

    12. Reconnect the generator set engine starting

    battery, negative (--) lead last.

    13. Reconnect utility power to the generator set.

    14. Press the AUTO button on the generator set

    controller.

    PIM Connection Specifications

    Input Rating 10 mA @ 12 VDC dry contact

    Output Relay Rating 10 A @ 120 VAC

    Wire Size 12--24 AWG

    Screw Torque 7 in. lbs

    Figure 6 Input/Output Connection Specifications

    15. Note the factory-assigned functions for the digital

    outputs shown in Figure 7. Use a personal

    computer connected to theRDC2or DC2 controller

    and Kohler SiteTech software to change the

    input and output functions, if necessary. Available

    input and output functions are listed in Figure 16

    and Figure 17. See TP-6701, SiteTech Software

    Operation Manual, for instructions.

    PIM Connection SiteTech Name

    DefaultSetting(Event)

    Input 1 TB2 IN1 Digital Input B1 None

    Input 2 TB2 IN2 Digital Input B2 None

    Output 1 TB3

    Relay 1

    Digital Output B1 Generator

    Running

    Output 2 TB3

    Relay 2

    Digital Output B2 Common Fault

    Output 3 TB4

    Relay 3

    Digital Output B3 Low Battery

    Voltage

    Output 4 TB4

    Relay 4

    Digital Output B4 Not in Auto

    Output 5 TB5

    Relay 5

    Digital Output B5 Cooldown

    Output 6 TB5

    Relay 6

    Digital Output B6 Normal Source

    Failure

    Figure 7 Inputs and Outputs

  • TT-1584 2/12a 5

    Communication Connections with

    Additional Accessories

    See Figure 9 through Figure 14 for connection options

    with up to three accessory modules. Accessory

    modules can include one Model RXT transfer switch,

    one programmable interface module (PIM), and/or one

    load control module (LCM).

    See Figure 8 for the maximum total cable length with 1,

    2, or 3 accessory modules per cable run.

    Use Belden #9402 (4-conductor) or equivalent

    20 AWG shielded, twisted-pair cable. Note the shield

    connections shown in Figure 9.

    If longer cable runs are required, #12--14 AWG wire

    can be used for the COMand PWR connections. The

    maximum total cable length is the value shown for

    #12 or #14 AWGwire in Figure 8. The 20 AWG cable

    used for communication connections A and B (only)

    can be as long as 152 m (500 ft.).

    Cable (TB1--PWR and COM)

    Maximum length per run, meters (ft.)

    Number of Modules (ATS, PIM, and LCM) per Run

    1 Module 2 Modules 3 Modules

    Belden #9402 or equivalent 20AWG 61 (200) 31 (100) 21 (67)

    14 AWG 152 (500) 152 (500) 122 (400)