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)

12 AWG 152 (500) 152 (500) 152 (500)

Figure 8 Total Cable Lengths with Accessory Modules Connected

PIM

LCM

Generator Set

COM

PWR

COM

PWR

B

A

B

A

COM

PWR

B

A


Leave one end of each cable shield disconnected at the last device.

RXT1

COM

PWR

B

A

COM

PWR

B

A

Connect shields togetheras shown.

1. Communication cable Belden #9402 or equivalent

20 AWG shielded, twisted-pair cable

GND

A

B

COM

PWR

3

4

TB1

NOTES:

See thegeneratorset InstallationManual for terminal

block location on generator set. Check the decal on

the generator set for terminal block connections.

See Figure 8 for maximum total cable length per run

(1 run shown)

Current transformer must be installed on theemergency source leads.

RBUS

12 VDCCOM

PWR

A

B

Figure 9 Communication Connection Details with Model RXT Transfer Switch

6 TT-1584 2/12a

LCM

Generator Set

COM

PWR

B

A


Leave one end of each cable shield disconnected at the last device.

PIM1

COM

PWR

B

A

COM

PWR

B

A

Connect shields togetheras shown.

1. Communication cable Belden #9402 or equivalent 20 AWG

shielded, twisted-pair cable2. Engine start leads 3 and 4. See the ATS manual for cable

size specifications.

GND

A

B

COM

PWR

3

4

TB1

NOTES:

See thegeneratorset InstallationManual for terminal

block location on generator set. Check the decal on

the generator set for terminal block connections.

See Figure 8 for maximum total cable length per run

(1 run shown)

Current transformer must be installed on theemergency source leads.

RBUS

12 VDCCOM

PWR

A

B

ATSModels RDTor RSB

2

2 4

3

Figure 10 Connection Details with Model RDT or RSB Transfer Switch

TT-1584 2/12a 7

NOTES:

See the generator set Installation Manual for terminal block location on

generator set. Check the decal on the generator set for terminal block

connections.

See Figure 8 for maximum total cable length per run (3 runs with 1module

each shown).

See Figure 9 for communication connection detail (A and B, PWR andCOM).

Use splices or wire nuts to collect multiple leads for connection to the

generator set terminal block. See Figure 12.

1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803

PIM

LCM

RXT ATS

Generator Set

TB1

1

1

1

Figure 11 Accessory Module Connections, Star Configuration (three cable runs with one module each)

1

tp6803

1. Splice

Generator Set

Generator Set Terminal Block TB1.See the generator set Installation Manual for location.Check the decal on the generator set for terminal block connections.

COM

PWR

B

A

Connect all of the shield leads on thisend to GROUND at the generator set.

COM

PWR

B

A

To GROUND

9402 CABLE

9402 CABLE

A

B

COM

PWR

3

4

TB1

RBUS

12 VDC

GND

Figure 12 Multiple Connections to the Generator Set

8 TT-1584 2/12a

1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803

PIM

LCM

RXT ATS1

1

1

Generator Set

TB1

NOTES:

See the generator set Installation Manual for terminal block

locationongenerator set. Check thedecalon thegenerator set for

terminal block connections.

See Figure 8 for maximum total cable length with12 or 14 AWG wire.

See Figure 9 for communication connection (A and B, PWR andCOM) detail. Connect the cable shield to ground at the generator

set.

Figure 13 Accessory Module Connections (two cable runs with one and two modules shown)

1. Belden #9402 or equivalent, 20 AWG shielded cable (use one pair); or

Belden #8762 or equivalent 20 AWG shielded cable2. 12--14 AWG wire

tp6803

PIM

LCM

RXT ATS

1

1

1

Generator Set A and BPWRCOM 2

2

22

2

2

A and B

A and B

A and B

PWRCOM

PWRCOM

PWRCOM

NOTES:

See the generator set Installation Manual for terminal block location on

generator set. Check the decal on the generator set for terminal block

connections.

SeeFigure 8 formaximum total cable length with 12 or 14 AWGwire. (1

run with 3 modules shown).

See Figure 9 for communication connection (A and B) detail. Connectthe cable shield to ground at the generator set.

Figure 14 Accessory Module Connections with 12--14 AWG Power Leads (one cable run with three modules

shown)

TT-1584 2/12a 9

PIM Inputs and Outputs

Connect customer-supplied equipment to the PIM input

and output connections. Connect to the normally open

or normally closed output contacts as required for the

application. See the wiring diagram for connection

details.

Run/Common Fault Outputs

The first two PIM outputs are factory-set to Generator

Running and Common Fault. See Figure 7. The

generator running output is activated when the

generator set is running. The common fault output is

activated on a fault.

Changing Input and Output Settings

Use a laptop computer connected to the RDC2 or DC2

controller and running Kohler SiteTech software to

change the event settings for factory-set inputs and

outputs. Be sure to select Digital Inputs B1--B2 and

Digital Outputs B1--B6 in SiteTech. See Figure 7 and

Figure 15. Digital Inputs A1--A2 and Digital Outputs

A1--A2 and B7--B12 do not apply to the PIM.

Note: SiteTech software is available to

Kohler-authorized distributors.

The available programmable input and digital output

functions are listed in Figure 16 and Figure 17. At

installation, note the input and output connections.

Then use Kohler SiteTech software to assign the

corresponding input and output functions if they are

different than the defaults shown in Figure 7.

1

tt15841. PIM Digital Input B1 settings

2. PIM Digital Output B3 settings

2

Figure 15 SiteTech Screen, Input and Output

Settings

Input Level

Auxiliary Input Shutdown

Auxiliary Input Warning

Battery Charger Fault Warning

Chicago Code Active Notice

Engine Fuel Level Critically High Warning

Engine Fuel Level High Warning

Engine Fuel Level Low Warning

Engine Fuel Level Low Shutdown

Engine Oil Level Low Warning

Engine Oil Level Low Shutdown

Fuel Pressure Low Warning

Fuel Tank Leak Shutdown

Fuel Tank Leak Warning

Ground Fault Input Warning

Remote Reset Status

* Some inputs do not apply to all models.

Figure 16 Programmable Inputs

10 TT-1584 2/12a

Digital Output Level * 14/20 48

AC Sensing Lost W

AC Sensing Lost S

Alternator Protection S NA NA

Always Off N

Always On N

ATS Fail To Transfer W

ATS Fail To Transfer S NA NA

ATS Phase RotationMismatch (3-phase only)

W NA

Auxiliary Input W

Auxiliary Input S

Battery Charger Fault W

Battery Voltage High W

Battery Voltage Low W

Chicago Code Active N

Common Fault N

Common Warning W

Cranking Voltage Low W

ECM Communication Loss S NA

Emergency Power SystemSupplying Load

N

Emergency Stop S NA

Engine Coolant Level Low S NA

Engine CoolantTemperature High

W NA

Engine CoolantTemperature High

S NA

Engine CoolantTemperature Low

W NA

Engine CoolantTemperature No Signal

S NA

Engine Cooldown Active N

Engine Fuel LevelCritically High

W

Engine Fuel Level High W

Engine Fuel Level Low W

Engine Fuel Level Low S

Engine Oil Level Low W

Engine Oil Level Low S

Engine Oil Pressure Low W NA

Engine Oil Pressure Low S

Engine Oil Pressure NoSignal

S NA

Engine Speed High S

Engine Speed Low S

Engine Start Aid Active N

Engine Start Delay Active N

Digital Output Level * 14/20 48

Fuel Pressure Low W

Fuel Spill N

Fuel Tank Leak S

Fuel Tank Leak W

Generator Frequency High S

Generator Frequency Low S

Generator Running N

Generator True TotalPower High

S NA NA

Generator Voltage L1--L2High

S

Generator Voltage L1--L2Low

S

Generator Voltage L2--L3High (3-phase only)

S NA

Generator Voltage L2--L3Low (3-phase only)

S NA

Generator Voltage L3--L1High (3-phase only)

S NA

Generator Voltage L3--L1Low (3-phase only)

S NA

Ground Fault Input W

Load Priority1 Shed ** Status NA NA






Locked Rotor S

Low Fuel N

Maximum AlternatorCurrent Low

S NA NA

Minor Fault N

NFPA 110 Alarm Active N

Not In Auto W

Over Crank S

Speed Sensor Fault S

System Ready N

* Level: N = Notice, S = Shutdown, W = Warning

Indicates output is remotely controlled through OnCue

Model RXT ATS required

From a digital input

Any of several conditions

** LCM required

NA: Not applicable for these models

Figure 17 Programmable Digital Outputs

TT-1584 2/12a 11

PIM Status Menu on the RDC2

Controller

The RDC2 controller displays PIM input and output

status in the menu shown in Figure 18. This is a status

display menu only. Input and output settings cannot be

changed from the RDC2 controllers user interface.

Refer to the generator set Operation Manual for

instructions to navigate the RDC2 menus, if necessary.

tp6810

PIMStatus:

PIM 1 ---->

12 TT-1584 2/12a

OnCue Remote Monitoring and

Control

The Kohler OnCue Generator Management System

can be used to monitor the PIM inputs and outputs with

your PC or laptop computer. OnCue can also be used to

remotely control PIM outputs 3 through 6 and to change

the output labels in OnCues Power Chain view.

Note: PIM outputs 1 and 2 are factory-set to Run and

Common Fault They are controlled by the

generator set and cannot be controlled remotely

through OnCue.

OnCue communicates with the PIM through the RDC2

or DC2 controller on the generator set. See the

generator set Installation Manual for instructions to

connect the generator set to the Internet.

The OnCue kit is available from Kohler authorized

distributors and dealers. See TP-6796, OnCue

Software Operation Manual, for instructions to use

OnCue on a personal computer.

Remote Control Example

1. Connect output 3 to the storm shutters on your

vacation home.

2. Use OnCue to connect to the generator set

controller and select the Power Chain view.

3. Select Edit Mode in the toolbar at the top of the

OnCue screen.

4. On the picture of the the PIM, click on the label for

output 3 and type in Storm Shutters.

5. Select Control Mode in the toolbar at the top of the

screen.

6. On the picture of the the PIM, click on Storm

Shutters to turn the output on or off. The status

indicator flashes for about 5 seconds and then

changes to show the new status: green for on or

gray for off.

When you click on an output in OnCues control mode,

the event setting changes from its original setting to On

or Off. The output can then only be controlled with

OnCue. It will no longer be controlled by the generator

set.

Kohler SiteTech software can be used to set the

outputs back to generator-controlled events, if

necessary. SiteTech is available to Kohler-authorized

distributors.

1

1. Edit mode and control mode selections

2. PIM outputs for remote control

2

Figure 19 OnCue Power Chain View

TT-1584 2/12a 13

TroubleshootingUse the flowcharts in Figure 20 through Figure 22 to

diagnose problems with the PIM operation.

Also see the next section, Verify that the Controller

Recognizes the PIM.

Check PIM outputstatus in controller

menu. SeeFigure 18.

Verify that only onePIM is connected.

Online LED may have adefect but does not affect

operation. Continuechecking functionality.

Check communication A & Bconnections at:1) PIM2) Genset connectionterminal block

Online LED Blinking

NO

YES

NO NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

PIM notresponding

Power LEDSteady ON? *

Online LEDSteady ON? *

Verify correct versionof PC software is

installed

Device shown onSiteTech/OnCue?

Verify I/O parametersare set up for desired

functionality

Number of errors andtimeouts steady?See Figure 25.

PIM ID does notchange over time.

LED blinking fasterthan once/second?

Ensure the cable runs fromgenset to PIM are withinspecifications (cable size andlength)

If problems persist, contactthe Kohler GeneratorService Department.

Go to Figure 21.

Go to Figure 22.

* See Figure 4 for LED locations on the PIM circuit board.

Figure 20 PIM Troubleshooting Chart, Part 1 of 3

14 TT-1584 2/12a

Is voltage lowbut not zero?

Check the cable sizeand length to verifythey are within therange shown in

Figure 8.

Check for 10--16 VDCat the PWR and COMconnections on the

generator set.

Check the wire runfrom generator set to

PIM.

NONO

YES

YES

Check voltage to thecontroller. See controllertroubleshootinginformation and wiringdiagrams in the generatorset service manual.

Check connectionsfrom controller to

customer connectionson generator set.YES

Power LED may have adefect but does not affect

operation. Continuechecking functionality.

Voltage between10 and 16 VDC?

Check power connection at:1) PIM2) Genset connectionterminal block3) Starting battery

NO

Power LEDis not lit

Figure 21 PIM Troubleshooting, Part 2 of 3, Troubleshooting Power to the PIM

Functions correctlyonly if connected

individually.

NO

YESYES

PIM functions correctlyonly after cycling power.

If problems persist, contactthe Kohler GeneratorService Department.

Disconnect RBUSmodules and verify thatSiteTech/OnCue showsno devices connected.

Verify that the maximumnumber of allowed devices

is not exceeded.

Verify that each deviceserial number is different.

NO

YES

YES

YES

YES

Verify that the USB cableis not connected to

generator controller duringpower cycles.

Verify that all devices areseen by SiteTech afterindividual connection

sequence.

Figure 22 PIM Troubleshooting Chart, Part 3 of 3

TT-1584 2/12a 15

Verify that the Controller Recognizes the PIM

There are two ways to verify that the RDC2 controller

recognizes the PIM.

On the RDC2 controller, navigate to the Networking

Menu and check the number of modules connected

and the information for remote devices. See

Figure 23 and Figure 24.

For the RDC2 or DC2 controller, use a laptop

computer connected to the controllers USB port and

KohlerOnCue or SiteTech software to check that

the PIM appears in the Power Chain view. See

Figure 19. In the Parameters view, check that the

RBUS network screen shows the correct number of

RBUS devices connected (RXT transfer switch, PIM,

and LCM, if used). See Figure 25.

tp6804

Modules Connected:3

Module Timeouts:1234

Net Cycle Time:123ms

Module Errors:1234

< ---- Return

RDRemote ---->Devices

See Figure 24.

Networking---->

Information

Networking---->

Status

RBUS ---->Information

Configuration

Figure 23 RDC2 Controller Menu, Networking Information

16 TT-1584 2/12a

tp6810

Device Status:Connected

RD

Firmware Ver.:122

ModBus ID:12

S/N: XXXXXXXXX

Return ---->

S/N: XXXXXXXXX

Comm. Errors:12345

Comm. Timeouts:12345

...

Connected:MM/DD/YY 12:12

TT-1584 2/12a 17

Figure 25 RBUS Device Parameters in OnCue or SiteTech

Parts List

Programmable Interface Module (PIM)

Kit: GM81529-KP1-QS

Qty. Description Part Number

1 PIM, Assy NEMA 3R GM81529-1

1 Installation Instructions TT-1584

Diagrams and Drawings

The PIM dimension drawing, wiring diagram, and

schematic are shown on the following pages.

18 TT-1584 2/12a

Figure 26 Dimension Drawing ADV-8199

TT-1584 2/12a 19

Figure 27 Wiring Diagram, GM84085

20 TT-1584 2/12a

Figure 28 Schematic Diagram, GM84086

Documents

Kohler Tt1584PIM