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Installation Procedure

Read the entire installation procedure and compare kit

parts with parts list in this publication before beginning

installation. Perform the steps in the order shown.

Note:

Observe applicable local and national electrical

codes when installing the wiring system.

Remove the generator set from service.

Note:

Refer to the procedures in the Safety Precautions

for disabling the generator set. The procedure to

shut down the generator set varies depending

upon the controller.

1.1

Shut down the generator set.

1.2

Disconnect the power to the battery charger, if

equipped.

1.3

Disconnect the generator set engine starting

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

1.4

Remove the controller cover and hardware.

Remove the gauge driver board in the

DEC 3+ controller (if equipped).

If the unit is an 80--150REOZJD or 450/500REOZVB

model, the controller may contain a gauge driver circuit

board GM49791-2. Information regarding identifying

the circuit board is shown in the Communication Module

for DEC 3+ Controller section of this document.

Note:

If the unit is not an 80--150REOZJD or 450/

500REOZVB model, go to step 3.

Note:

If the communication module board GM49791-1

is already installed because GM91356-S4, -S5,

or -S6 kit was ordered

installed

, go to step 5.

Otherwise, remove GM49791-2 interface with gauge

driver circuit board and replace with GM49791-1

communication interface with gauge driver circuit

board.

Use the following procedure and refer to

Figure 9.

2.1

Disconnect the 10-pin cable at the P8 connector

on the circuit board.

2.2

Disconnect the 8-pin cable at the P10 connector

on the circuit board.

2.3

Remove the existing three nuts and lock washers

attaching the gauge drive circuit board to the

indicator panel circuit board. Leave the existing

washers in place. The nuts and lock washers will

be reused.

2.4

Remove existing 24-position ribbon cable

336428 between the indicator panel circuit board

and the main circuit board. This ribbon cable will

not be reused.

2.5

The new 24-position ribbon cable GM32632 has

three connectors—one at each end and an inline

connector. Attach the end connector (nearest to

inline connector) to the indicator panel circuit

board P4 connector. The connector is polarized

and mates in one position only.

2.6

Attach the other end connector of the 24-position

ribbon cable GM32632 to the main circuit board

P3 connector. The connector is polarized and

mates in one position only.

Содержание APM802

Страница 1: ...tery such as the engine starting battery AC adaptor kit GM62466 KP1 is available when NFPA is not required The front panel decals include areas that can be used to identify user selected fault inputs...

Страница 2: ...features of the RSA III If the RSA III is used with an Ethernet communication network order Modbusr Ethernet converter GM41143 KP2 and refer to TT 1405 Converters Connections and Controller Setup for...

Страница 3: ...or EPS supplying load Note Some controllers have programmable digital outputs that can be programmed to common faults and wired to user inputs 1 through 5 These inputs will activate the horn only if t...

Страница 4: ...rt A USB port located on the front panel allows user setup of the RSA III using a PC and SiteTecht software LEDs There are up to 33 LED indicators on the non ATS model up to 41 LED indicators on the s...

Страница 5: ...Input 2 Warning Yellow SF Green Green or Off Green Off Off Off User Input 2 Shutdown Red FF Green Green or Off Green Off On On User Input 3 Warning Yellow SF Green Green or Off Green Off Off Off User...

Страница 6: ...Terminal 32 on the DEC 3 provides the following ten common faults D Auxiliary Warning D Generator Switch Not In Auto D High Engine Temperature Shutdown D High Engine Temperature Warning D Low Water T...

Страница 7: ...oolant level switch on remote radiator models Low Coolant Temperature Yellow LED flashes when optional engine block heater malfunctions and or engine coolant temperature is too low Requires prealarm s...

Страница 8: ...ng or Flush Mounting capability is standard This document includes installation information for both surface and flush mount models Safety Precautions Observe the following safety precautions while in...

Страница 9: ...Makerr 8000 Controller Hot surfaces CAUTION APM802 Controller Heater Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel...

Страница 10: ...odel go to step 3 Note If the communication module board GM49791 1 is already installed because GM91356 S4 S5 or S6 kit was ordered installed go to step 5 Otherwise remove GM49791 2 interface with gau...

Страница 11: ...91 2 gauge driver board was previously installed connect P10 to the communication module board to drive coolant temperature and oil pressure gauges on the DEC 3 controller 8 Lead GM35318 connecting T2...

Страница 12: ...ine connector to the communication module board P9 connector The connector is polarized and mates in one position only 4 2 Attach the 10 position ribbon cable GM21340 to the communication module board...

Страница 13: ...tions are defined in Figure 12 and include D User Input 1 remote D User Input 2 remote Note User input 3 is reserved for high battery voltage as outlined in step 4 4 Document the user selected inputs...

Страница 14: ...14 TT 1625 7 17 Figure 15 Remote Serial Annunciator Dimension Print ADV 8661A...

Страница 15: ...TT 1625 7 17 15 Figure 16 Remote Serial Annunciator Dimension Print ADV 8661B modified...

Страница 16: ...ed in the wall 5 3 2 Create an opening in the wall for the electrical wiring from the master RSA III to the controller communications and power supply The wall opening must allow for the wiring of the...

Страница 17: ...d conduit connector or bushing Temporarily install the RSA III front panel assembly to be sure the hole location with bushing or conduit connector does not interfere with attaching the RSA III front p...

Страница 18: ...re 20 RSA III Circuit Board GM86125 Connectors The RSA III has the following wiring and selections D P27 6 pin RS 485 connections communication between controller and RSA III master See step 6 3 D P27...

Страница 19: ...ition only See Figure 22 for a typical RS 485 connection Communication between RSA III Master and RSA III Slave Figure 23 shows the master slave RS 485 connections and Figure 20 shows the RSA III with...

Страница 20: ...d Shield Note When using RS 485 communication cable connect the shield wire at the RSA III P27 connection but not at the APM802 controller TB10 connection Figure 26 APM802 RS 485 Connections on TB10 D...

Страница 21: ...end but not at both ends Figure 30 DEC 3000 P21 RS 485 Connections DEC 3500 Controller Figure 31 shows the DEC 3500 controller with TB12 location and Figure 32 shows the RS 485 connections 1 TB12 con...

Страница 22: ...shield wire at either end but not at both ends Figure 33 DEC 550 and DEC 6000 Controllers P20 RS 485 Connections TT 1377 1 Main circuit board top view 2 P21 for KBus RS 485 communication connection 3...

Страница 23: ...plug 294619 included and plug into the RSA III circuit board The Euroblock connector is polarized and attaches in one position only Each RSA III is shipped with a termination resistor in the NON TERMI...

Страница 24: ...tion at the engine ground Do not use terminals 42A and 2 on the controller connection kit terminal strip The battery positive lead should be fuse protected AC adapter kit GM62466 KP1 is available to s...

Страница 25: ...as the RSA III circuit board When the slave RSA III is not the only item on the network use the isolated connection where the RS 485 cable shield and ground leads are connected but not grounded to th...

Страница 26: ...o user defined digital input selection is available at the RSA III slave s Controller User Input 4 User Input 5 Master RSA III Local P42 1 user selectable P42 2 ground P42 3 user selectable P42 4 grou...

Страница 27: ...1 D7 2 D8 3 D10 Figure 46 RSA III Remote User Inputs with DEC 550 and DEC 6000 Controllers 6 12 DEC 8000 Controllers only For the user defined digital inputs 1 to 5 on the RSA III use the controller b...

Страница 28: ...lation Proceed to either Step 7 1 Surface mount RSA III final installation or Step 7 2 Flush mount RSA III final installation 7 1 Surface mount RSA III final installation 7 1 1 Mount the RSA III box t...

Страница 29: ...with red controller board or 2 03 or higher with blue controller board 8 4 Replace the controller cover and hardware 9 Restore the generator set to service 9 1 Place the generator set master switch i...

Страница 30: ...DEC 3000 DEC 3500 controllers for the remote serial annunciator The Decision Makerr 3000 and 3500 controllers default to a 19200 baud rate and to a Modbusr address 1 If the Modbusr settings need to be...

Страница 31: ...TT 1625 7 17 31 Figure 53 RSA III Generator Set and ATS Setup on SiteTecht Sample Screen...

Страница 32: ...the four fields D Connected GenSet d Product d Address d Timeout D Connected ATS d Connected d Product d Address d Timeout D Connected Annunciator 1 d Product d Address d Timeout D Connected Annunciat...

Страница 33: ...ciator 4 Product none See Annunciator List Connected Slave Annunciator 4 Address 6 If RSA 1000 then 247 1 247 Connected Slave Annunciator 4 Timeout 45 seconds w 1 120 seconds Connected Slave Annunciat...

Страница 34: ...dresses based on the range of 1 247 In addition each field creates addresses for each of the RSA III slaves Up to five slaves can be driven by one RSA III master The Modbusr Timeout period is separate...

Страница 35: ...TP 6914 Industrial or TP 6861 Marine Wiring diagram for the respective generator set Remote Generator Set Decision Makerr 6000 6 11 TP 6750 Wiring diagram for the respective generator set Remote Gene...

Страница 36: ...36 TT 1625 7 17 Figure 57 RSA III Wiring Diagram GM62554A J...

Страница 37: ...TT 1625 7 17 37 Figure 58 RSA III Wiring Diagram GM62554B J...

Страница 38: ...38 TT 1625 7 17 Figure 59 RSA III Wiring Diagram GM62554C J...

Страница 39: ...TT 1625 7 17 39 Figure 60 RSA III Wiring Diagram GM62554D J...

Страница 40: ...40 TT 1625 7 17 Figure 61 RSA III Wiring Diagram GM62554E J...

Страница 41: ...TT 1625 7 17 41 Figure 62 RSA III Wiring Diagram GM62554F J...

Страница 42: ...42 TT 1625 7 17 Figure 63 RSA III Wiring Diagram GM62554G J...

Страница 43: ...TT 1625 7 17 43 Figure 64 RSA III Interconnection Diagram ADV 6990A H...

Страница 44: ...44 TT 1625 7 17 Figure 65 RSA III Interconnection Diagram ADV 6990B H...

Страница 45: ...n GM62619 GM62619 GM62619 GM62619 GM62619 GM62619 GM62619 GM62619 GM62619 1 Euroblock plug 8 position GM62699 GM62699 GM62699 GM62699 GM62699 GM62699 GM62699 GM62699 GM62699 1 Bezel GM85134 GM85134 GM...

Страница 46: ...46 TT 1625 7 17 Notes...

Страница 47: ...TT 1625 7 17 47 Notes...

Страница 48: ...stems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 Availability is subject to change without notice Kohler Co reserves the right to change the desi...

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