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TT-1584

INSTALLATION INSTRUCTIONS
Original Issue Date: Model: Market: Subject: 2/12 14RESA/RESAL, 20RESA/RESAL, and 48RCL Residential/Light Commercial Programmable Interface Module (PIM) Kits GM81529-KP1-QS

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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 Kohlerr RDC2 or DC2 controller, including the following models:
D 14RESA/RESAL D 20RESA/RESAL D 48RCL

Inputs and outputs are factory-set to the events 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 Kohlerr SiteTecht software . SiteTech is available to Kohler-authorized distributors. A maximum of three accessory modules can be connected to the generator set. Accessory modules 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.

The PIM is mounted in a NEMA 3R enclosure, which can be installed indoors or outdoors. The PIM with enclosure is shown in Figure 1. For outdoor installation, use watertight conduit hubs.

OnCue Remote Monitoring and Control


The Kohlerr OnCuer Generator Management System can be used to monitor the PIM inputs and outputs. OnCue can also be used to remotely control PIM outputs 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.

ADV--8199

Figure 1

Programmable Interface Module (cover removed for illustration)

Safety Precautions
Observe the following safety precautions while installing the kit.

5. Cut holes in the PIM enclosure 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, and COM on 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, see Communication Connections with Additional Accessories on page 5.

WARNING

Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch.

DANGER

1 Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.

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.
1. Customer connection terminal block
ADV-7876

Figure 2

14/20RESA Terminal Block Location

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1 7

2 3 4 1

6 5

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1. Customer connection terminal block Note: Access panel removed for illustration. 1. 2. 3. 4. 5. 6. 7. TB4, relay 3 and relay 4 connections P10, connection to generator set TB2, input 1 and input 2 connections LED1, online TB3, relay 1 and relay 2 connections TB5, relay 5 and relay 6 connections LED2, power

ADV--8199

Figure 3

Model 48RCL Terminal Block Location

Figure 4
Connect one end of each cable shield to GROUND at the generator set.

PIM Circuit Board Connections and LEDs

GND

PIM
A B PWR COM

Generator Set
RBUS

A B

12 VDC PWR
COM 4 3 TB1

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

NOTE: See Figure 2 or Figure 3 for the terminal block location on the generator set. Check the decal on the generator set for terminal block connections. 1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable

Figure 5

PIM Communication Connections to Generator Set

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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 Output Relay Rating Wire Size Screw Torque 10 mA @ 12 VDC dry contact 10 A @ 120 VAC 12--24 AWG 7 in. lbs

15. Note the factory-assigned functions for the digital outputs shown in Figure 7. Use a personal computer connected to the RDC2 or DC2 controller and Kohlerr SiteTechr 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.
Default Setting (Event) None None Generator Running Common Fault Low Battery Voltage Not in Auto Cooldown Normal Source Failure

PIM Connection Input 1 Input 2 Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 TB2 IN1 TB2 IN2 TB3 Relay 1 TB3 Relay 2 TB4 Relay 3 TB4 Relay 4 TB5 Relay 5 TB5 Relay 6

SiteTech Name Digital Input B1 Digital Input B2 Digital Output B1 Digital Output B2 Digital Output B3 Digital Output B4 Digital Output B5 Digital Output B6

Figure 7

Inputs and Outputs

Figure 6

Input/Output Connection Specifications

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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.

D Use Belden #9402 (4-conductor) or equivalent

20 AWG shielded, twisted-pair cable. Note the shield connections shown in Figure 9.
D If longer cable runs are required, #12--14 AWG wire

can be used for the COM and PWR connections. The maximum total cable length is the value shown for #12 or #14 AWG wire in Figure 8. The 20 AWG cable used for communication connections A and B (only) can be as long as 152 m (500 ft.).

Maximum length per run, meters (ft.) Number of Modules (ATS, PIM, and LCM) per Run Cable (TB1-PWR and COM) Belden #9402 or equivalent 20AWG 14 AWG 12 AWG 1 Module
61 152 152 (200) (500) (500)

2 Modules
31 152 152 (100) (500) (500)

3 Modules
21 122 152 (67) (400) (500)

Figure 8

Total Cable Lengths with Accessory Modules Connected

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

Connect shields together as shown.

GND

RXT
A B PWR COM A B PWR COM A B PWR COM

Generator Set
RBUS

A B

12 VDC PWR
COM 4 3 TB1

PIM
NOTES:

D See the generator set Installation Manual for terminal


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

A B PWR COM

A B PWR COM

D See Figure 8 for maximum total cable length per run


(1 run shown)

D Current transformer must be installed on the


emergency source leads.

A B PWR COM

LCM

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

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

Figure 9
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Communication Connection Details with Model RXT Transfer Switch


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

Connect shields together as shown.

GND

PIM
A B PWR COM A B PWR COM A B PWR COM

Generator Set
RBUS

A B

12 VDC PWR
COM 4 3 TB1

NOTES:

A B PWR COM

D See the generator set Installation Manual for terminal


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

LCM

D See Figure 8 for maximum total cable length per run


(1 run shown) Leave one end of each cable shield disconnected at the last device.

D Current transformer must be installed on the


emergency source leads.

ATS Models RDT or RSB


2 2

4 3

1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable 2. Engine start leads 3 and 4. See the ATS manual for cable size specifications.

Figure 10 Connection Details with Model RDT or RSB Transfer Switch

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RXT ATS Generator Set TB1


1 1

LCM

NOTES:

D See the generator set Installation Manual for terminal block location on
generator set. Check the decal on the generator set for terminal block connections.

PIM

D See Figure 8 for maximum total cable length per run (3 runs with 1 module
each shown).

D See Figure 9 for communication connection detail (A and B, PWR and


COM).

D 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

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

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

1 GND

A B 9402 CABLE PWR COM

Generator Set
RBUS 12 VDC
A B PWR COM 4 3 TB1 To GROUND

A B PWR COM

9402 CABLE

Generator Set Terminal Block TB1. See the generator set Installation Manual for location. Check the decal on the generator set for terminal block connections. 1. Splice

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Figure 12 Multiple Connections to the Generator Set

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Generator Set TB1


1

RXT ATS

NOTES:

PIM
1

D See the generator set Installation Manual for terminal block


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

D See Figure 8 for maximum total cable length with


12 or 14 AWG wire.

D See Figure 9 for communication connection (A and B, PWR and


COM) detail. Connect the cable shield to ground at the generator set.

LCM

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

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

RXT ATS Generator Set A and B PWR COM


1 2 2

A and B PWR COM

1 2 2

PIM
NOTES:

D See the generator set Installation Manual for terminal block location on
generator set. Check the decal on the generator set for terminal block connections.

A and B PWR COM


1 2 2

D See Figure 8 for maximum total cable length with 12 or 14 AWG wire. (1
run with 3 modules shown).

D See Figure 9 for communication connection (A and B) detail. Connect


the cable shield to ground at the generator set.

LCM A and B PWR COM


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1. Belden #9402 or equivalent, 20 AWG shielded cable (use one pair); or Belden #8762 or equivalent 20 AWG shielded cable 2. 12--14 AWG wire

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

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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 Kohlerr SiteTecht 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: SiteTecht software is Kohler-authorized distributors. available to
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1. PIM Digital Input B1 settings 2. PIM Digital Output B3 settings

Figure 15 SiteTech Screen, Input and Output Settings


Input Auxiliary Input Auxiliary Input Battery Charger Fault Chicago Code Active Engine Fuel Level Critically High Engine Fuel Level High Engine Fuel Level Low Engine Fuel Level Low Engine Oil Level Low Engine Oil Level Low Fuel Pressure Low Fuel Tank Leak Fuel Tank Leak Ground Fault Input Remote Reset
* Some inputs do not apply to all models.

Level Shutdown Warning Warning Notice Warning Warning Warning Shutdown Warning Shutdown Warning Shutdown Warning Warning Status

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 Kohlerr SiteTecht software to assign the corresponding input and output functions if they are different than the defaults shown in Figure 7.

Figure 16 Programmable Inputs

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Digital Output AC Sensing Lost AC Sensing Lost Alternator Protection Always Off ] Always On ] ATS Fail To Transfer ATS Fail To Transfer ATS Phase Rotation Mismatch (3-phase only) Auxiliary Input w Auxiliary Input w Battery Charger Fault w Battery Voltage High Battery Voltage Low Chicago Code Active w Common Fault [ Common Warning [ Cranking Voltage Low ECM Communication Loss Emergency Power System Supplying Load Emergency Stop Engine Coolant Level Low Engine Coolant Temperature High Engine Coolant Temperature High Engine Coolant Temperature Low Engine Coolant Temperature No Signal Engine Cooldown Active Engine Fuel Level Critically High w Engine Fuel Level High w Engine Fuel Level Low w Engine Fuel Level Low w Engine Oil Level Low w Engine Oil Level Low w Engine Oil Pressure Low Engine Oil Pressure Low Engine Oil Pressure No Signal Engine Speed High Engine Speed Low Engine Start Aid Active Engine Start Delay Active

Level * W S S N N W S W W S W W W N N W W S N S S W S W S N W W W S W S W S S S S N N

14/20 D D NA D D D NA NA D D D D D D D D D NA D NA NA NA NA NA NA D D D D D D D NA D NA D D D D

48 D D NA D D D NA D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D

Digital Output Fuel Pressure Low w Fuel Spill [w Fuel Tank Leak w Fuel Tank Leak w Generator Frequency High Generator Frequency Low Generator Running Generator True Total Power High Generator Voltage L1--L2 High Generator Voltage L1--L2 Low Generator Voltage L2--L3 High (3-phase only) Generator Voltage L2--L3 Low (3-phase only) Generator Voltage L3--L1 High (3-phase only) Generator Voltage L3--L1 Low (3-phase only) Ground Fault Input w Load Priority1 Shed ** Load Priority2 Shed ** Load Priority3 Shed ** Load Priority4 Shed ** Load Priority5 Shed ** Load Priority6 Shed ** Locked Rotor Low Fuel [w Maximum Alternator Current Low Minor Fault [ NFPA 110 Alarm Active Not In Auto Over Crank Speed Sensor Fault System Ready

Level * W N S W S S N S S S S S S S W Status Status Status Status Status Status S N S N N W S S N

14/20 D D D D D D D NA D D NA NA NA NA D NA NA NA NA NA NA D D NA D D D D D D

48 D D D D D D D NA D D D D D D D NA NA NA NA NA NA D D NA D D D D D D

* Level: N = Notice, S = Shutdown, W = Warning ] Indicates output is remotely controlled through OnCuer Model RXT ATS required w From a digital input [ Any of several conditions ** LCM required NA: Not applicable for these models

Figure 17 Programmable Digital Outputs

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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.

PIM Status:

PIM 1

---->

Input 1 In/Active

<---- Return

Input 2 In/Active Output 1: In/Active Output 2: In/Active Output 3: In/Active Output 4: In/Active Output 5: In/Active

Output 6: In/Active

<---- Return
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Figure 18 PIM Status Menu

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OnCue Remote Monitoring and Control


The Kohlerr OnCuer 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. Kohlerr SiteTecht software can be used to set the outputs back to generator-controlled events, if necessary. SiteTech is available to Kohler-authorized distributors.

1. Edit mode and control mode selections 2. PIM outputs for remote control

Figure 19 OnCue Power Chain View


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Troubleshooting
Use 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.

PIM not responding

Power LED Steady ON? * YES Online LED Steady ON? * YES

NO Go to Figure 21.

NO Online LED Blinking YES

NO

Online LED may have a defect but does not affect operation. Continue checking functionality.

Verify correct version of PC software is installed

NO

Device shown on SiteTech/OnCue? YES

LED blinking faster than once/second? YES

NO

Verify that only one PIM is connected.

Verify I/O parameters are set up for desired functionality YES Check PIM output status in controller menu. See Figure 18.

Number of errors and timeouts steady? See Figure 25. YES PIM ID does not change over time. YES

NO

Check communication A & B connections at: 1) PIM 2) Genset connection terminal block

NO

Ensure the cable runs from genset to PIM are within specifications (cable size and length)

Go to Figure 22. If problems persist, contact the Kohler Generator Service Department.

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

Figure 20 PIM Troubleshooting Chart, Part 1 of 3

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Power LED is not lit

Check power connection at: 1) PIM 2) Genset connection terminal block 3) Starting battery

Voltage between 10 and 16 VDC? YES

NO

Is voltage low but not zero? YES

NO

Check for 10--16 VDC at the PWR and COM connections on the generator set. YES

NO

Check connections from controller to customer connections on generator set.

Power LED may have a defect but does not affect operation. Continue checking functionality.

Check the cable size and length to verify they are within the range shown in Figure 8.

Check the wire run from generator set to PIM.

Check voltage to the controller. See controller troubleshooting information and wiring diagrams in the generator set service manual.

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

PIM functions correctly only after cycling power. YES

NO

Functions correctly only if connected individually. YES Verify that the USB cable is not connected to generator controller during power cycles. YES Verify that all devices are seen by SiteTech after individual connection sequence.

NO

Disconnect RBUS modules and verify that SiteTech/OnCue shows no devices connected. YES

Verify that the maximum number of allowed devices is not exceeded. YES

Verify that each device serial number is different.

YES

If problems persist, contact the Kohler Generator Service Department.

Figure 22 PIM Troubleshooting Chart, Part 3 of 3

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Verify that the Controller Recognizes the PIM There are two ways to verify that the RDC2 controller recognizes the PIM.
D 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.
D For the RDC2 or DC2 controller, use a laptop

Kohlerr OnCuer or SiteTecht 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.

computer connected to the controllers USB port and

Networking----> Information

Networking----> Status

Networking----> Configuration

RBUS ----> Information

Modules Connected: 3

<---- Return

Remote ----> Devices

RD See Figure 24.

Net Cycle Time: 123ms

Module Timeouts: 1234

Module Errors: 1234

< ---- Return


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Figure 23 RDC2 Controller Menu, Networking Information

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From Figure 23.

RD

S/N: XXXXXXXXX <<*DeviceType*>>

S/N: XXXXXXXXX <<*DeviceType*>>

...

<---- Return

Device Status: Connected

Comm. Errors: 12345

Comm. Timeouts: 12345

ModBus ID: 12

Firmware Ver.: 122 Connected: Displays date/time device was connected. Disconnected: Displays date/time of the last successful communication.
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Connected: MM/DD/YY 12:12

Return ---->

Figure 24 RDC2 Remote Devices Submenu

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Figure 25 RBUS Device Parameters in OnCue or SiteTech

Parts List
Programmable Interface Module (PIM)
Kit: GM81529-KP1-QS Qty. Description
1 1 PIM, Assy NEMA 3R Installation Instructions

Diagrams and Drawings


The PIM dimension drawing, wiring diagram, and schematic are shown on the following pages.

Part Number
GM81529-1 TT-1584

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Figure 26 Dimension Drawing ADV-8199

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Figure 27 Wiring Diagram, GM84085

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Figure 28 Schematic Diagram, GM84086

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