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Original Issue Date: 3/14
Model: Generator Sets with APM802 Controller; Decision-Makerr 3+, 550, 3000,
Market: Industrial
Subject: Remote Serial Annunciator (RSA III) Kits (Firmware Version 1.0)
Introduction
RSA III is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA III is a remote serial annunciator (Figure 1,
Figure 2, and Figure 3) that monitors the condition of
the generator set and/or ATS from a remote location.
The RSA III alerts the operator through visual and
audible signals using LED indication and a horn. An
alarm silence and lamp test switch are included.
The RSA III meets NFPA 110, Level 1 applications that
require remote controls and alarms be powered by a
storage battery 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
associated power system equipment.
Figure 1 Remote Serial Annunciator (RSA III)
An RSA III annunciator can be used for a single
generator set (Figure 1) or with a combination of a
generator set and automatic transfer switch(es)
(Figure 2 or Figure 3). In systems using more than a
single RSA III, one must be designated as the master
device to broadcast to additional RSA III annunciators,
designated as slave devices. Up to five RSA III slave

INSTALLATION INSTRUCTIONS

3500, 6000, and 8000 Controllers; and KPC 1000 Controller
Transfer Switches with Decision-Makerr MPAC 750, 1000, 1200, and 1500
Controllers
fault
inputs
and
identify
devices can be used with an RSA III master device. All
RSA III annunciators are factory set as the master
device, but can be changed to a slave device using a PC
and SiteTecht software that connects to the RSA III
front panel via a universal serial bus (USB) connection.
The RSA II can be connected with the RSA III provided
that the master remote annunciator is an RSA III.
Figure 2 RSA III with Single ATS Control
Figure 3 RSA III with Four ATS Controls
TT-1625 7/17c

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Summary of Contents for Kohler APM802

  • Page 1 TT-1625 7/17c INSTALLATION INSTRUCTIONS Original Issue Date: 3/14 Model: Generator Sets with APM802 Controller; Decision-Makerr 3+, 550, 3000, 3500, 6000, and 8000 Controllers; and KPC 1000 Controller Transfer Switches with Decision-Makerr MPAC 750, 1000, 1200, and 1500 Controllers Market: Industrial Subject: Remote Serial Annunciator (RSA III) Kits (Firmware Version 1.0)
  • Page 2 RSA III The RSA III is compatible with the following controllers: master and then power up the RSA III master so APM802 (compatible with RSA firmware version that the RSA III master can recognize the 2.0.8 or higher) changes.
  • Page 3 Communication Module for DEC 3+ RSA III Features Controller Horn GM47242 Circuit Board. Communication module for Alarm Horn. The alarm horn sounds giving a minimum all generator set models except 450/500REOZVB and 70 dB at 0.1 m (0.3 ft.) audible alarm when a warning or 80--150REOZJD;...
  • Page 4 LEDs To start a loaded remote test The front panel of the RSA III has an ATS TEST There are up to 33 LED indicators on the non-ATS pushbutton for every displayed ATS. The ATS TEST model, up to 41 LED indicators on the single ATS model, pushbutton will only operate when the control keyswitch and up to 65 LED indicators on the multiple ATS model is in the unlock position and the ATS is not in local-test...
  • Page 5 System Monitoring LEDs and Functions Common System Generator Communications Common Fault Fault Ready LED Running LED Status LED Fault LED Output Horn Fault and Status Condition Overcrank (Shutdown) Red SF Red SF Green Red SF High Engine Temperature (Warning) Yellow SF Red SF Green Green...
  • Page 6 High Engine Temperature Warning Master RSA III Automatic Low Water Temperature Warning Slave RSA(s) Not applicable Not accessible Low Fuel Warning APM802 Via SiteTecht Low Oil Pressure Shutdown Decision-Makerr 3+ Via SiteTecht Low Oil Pressure Warning Decision-Makerr 550 Via SiteTecht...
  • Page 7 Emergency Power System (EPS) Supplying Load. Low Coolant Temperature. Yellow LED flashes when (RSA III with ATS only). Use the SiteTecht software to optional engine block heater malfunctions and/or select the EPS source from the following choices: engine coolant temperature is too low. Requires prealarm sender on some generator set models.
  • Page 8 Reconnect the negative (--) lead last when reconnecting the battery. unless altered using SiteTecht. Any digital input from the Kohler generator controllers and ATS can be associated with any of the five user input LEDs. Disabling the generator set. Accidental starting can cause severe injury or death.
  • Page 9 Hot surfaces. Disconnect all power sources before opening the enclosure. (APM802 Controller Heater) Accessing the middle compartment on the control panel. Hazardous voltage can cause severe injury or death. On the controller base box and automatic voltage regulator, do not touch the terminals for voltage and current measurement.
  • Page 10 Installation Procedure Remove the gauge driver board in the DEC 3+ controller (if equipped). Read the entire installation procedure and compare kit parts with parts list in this publication before beginning If the unit is an 80--150REOZJD or 450/500REOZVB installation. Perform the steps in the order shown. model, the controller may contain a gauge driver circuit board GM49791-2.
  • Page 11 Legend CMB—Communication Module Board IPA—Indicator Panel Assembly (P#)—Plug TB1, TB2—Controller Board Terminal Block TB5—Communication Interface Board Terminal Block GM32644-F 1. P22 CAN (engine) communication connection 2. DEC 3+ controller main circuit board 3. P21 RS-485 communication connection for remote serial annunciator 4.
  • Page 12 Mount the communication module board in the DEC 3+ controller. Note: Requires DEC 3+ controller logic (red) circuit board GM28725. Note: Perform step 3 with GM91356-S4, -S5, or -S6 and GM32644-KP1 kit. Remove the existing three nuts attaching the indicator panel circuit board. Leave the existing washers in place.
  • Page 13 Document the user-selected inputs for future Connector Designation Circuit Board Designation reference. If user-selected inputs 1--2 (remote) Not used are used, the user may add the identification on Not used the RSA III front panel strip. This procedure is ATS Position Input Return further explained in step 6.13 of this instruction.
  • Page 14 Figure 15 Remote Serial Annunciator Dimension Print ADV-8661A- TT-1625 7/17...
  • Page 15 Figure 16 Remote Serial Annunciator Dimension Print ADV-8661B- (modified) TT-1625 7/17...
  • Page 16 Note: Dimensions shown are in mm. 25.4 mm is equal to 1 inch. GM85125-A Figure 17 RSA III Mounting Hole Dimensions in Supplied Box GM85123 Remove four screws X-67-154 from the RSA III 5.3.3 Drill an appropriate size hole in box bezel GM85134 and remove bezel from the GM85125 if a user-supplied conduit RSA III box GM85123.
  • Page 17 5.4.2 Drill an appropriate size hole in box Size the flexible conduit for the electrical wiring GM85123 if a user-supplied conduit from the master RSA III to the controller connector is required. Install the user- communications and power supply. supplied connector. flexible conduit size must allow for the wiring of RSA III slave, if used.
  • Page 18 Use solid or stranded 14-22 gauge wire. To determine Throughout step 6, refer to the following illustrations. the wire gauge, measure the cable distance between See Figure 20 for RSA III circuit board connectors. See the controller and master RSA III. Figure 41 for RSA III circuit board terminal connections.
  • Page 19 RSA III, are considered slaves. If the controller is the last device in the network, use a terminating resistor on the controller. Figure 22. APM802 DEC 8000 controllers have a terminating resistor located on the controller. See Figure 36 and Figure 24.
  • Page 20 Do not connect at TB10 or base module; Shield tape to insulate unused end. 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 TT-1625 7/17...
  • Page 21 DEC 3000 Controller. Figure 29 shows the DEC 3500 Controller. Figure 31 shows the DEC 3000 controller with P21 location and DEC 3500 controller with TB12 location and Figure 30 shows the RS-485 connections. Figure 32 shows the RS-485 connections. 1.
  • Page 22 DEC 550 Controller. Figure 33 shows the RS-485 connections and Figure 34 shows the DEC 550 controller with P20 location. DEC 6000 Controller. Figure 33 shows the RS-485 connections and Figure 35 shows the DEC 6000 controller with P20 location. Circuit Board Wire Connector...
  • Page 23 RSA III, are considered slaves. If the controller is the last device in the network, use a terminating resistor on the controller. The APM802 and DEC 8000 controllers have a terminating resistor located on the controller. See Figure 36 and Figure 24.
  • Page 24 P37, 3-pin power connections. Each RSA III P37 Power Connections requires a 12/24-volt, 200 mA (min.) DC power P37-1 Ground source. The RSA III voltage should match the P37-2 12/24 VDC battery input1 (not polarity sensitive) generator set starting system. Provide an engine P37-3 12/24 VDC battery input2 (not polarity sensitive) starting battery connection to P37.
  • Page 25 P39, 3-pin isolated/non-isolated jumper. See P40, 6-pin common fault output and horn dry Figure 39 for P39 connections. See Figure 20 for contacts. These dry contact relays energize the location of P39 on the RSA III. when the alarm horn sounds and activate user-supplied devices.
  • Page 26 P41, 8-pin input (EPS/user) connections. See Make additional local user-selected Figure 20 for location of P41 on the RSA III. See connections to the RSA III P41 connector. User- Figure 41 for P41 User Input 1--3 Connections. defined inputs can be used for any status, See Figure 42 for P42 User Input 4--5 warning, or shutdown including open circuit Connections...
  • Page 27 6.10 APM802 Controllers only. For the user-defined 6.12 DEC 8000 Controllers only. digital inputs 1 to 5 on the RSA III, use the user-defined digital inputs 1 to 5 on the RSA III, controller digital inputs connections located on use the controller binary inputs connections TB10.
  • Page 28 7.2.3 Center the remote annunciator in the box DEC 550 and DEC 6000 controllers and the and position wall-mounting plate square access panels on the DEC 8000 and APM802 with the wall. Tighten the screws. controllers. 7.2.4 Proceed to step 8.
  • Page 29 Reset alarm horns as needed. 10. Configure the APM802 controllers for the remote serial annunciator. OPEN The APM802 is factory configured to work with the 6126 1. Push this side down to open circuit. RSA III. The APM802 controller defaults to a 19200 baud rate and to an address of #1.
  • Page 30 11. Configure the DEC 550 and DEC 6000 12. Configure the DEC 3000/DEC 3500 controllers for the remote serial controllers for the remote serial annunciator. annunciator. Note: Refer to the DEC 550 (TP-6200) or DEC 6000 The Decision-Makerr 3000 and 3500 controllers default (TP-6750) controller operation manual as to a 19200 baud rate and to a Modbusr address #1.
  • Page 31 Figure 53 RSA III Generator Set and ATS Setup on SiteTecht (Sample Screen) TT-1625 7/17...
  • Page 32 The Menu List Summary indicates the various displays during the setup. The RSA III default settings and within the SiteTecht software screens. Some displays ranges provide guidelines. Non-adjustable user- are read only while other fields require user input to set defined settings are factory-set or firmware controlled.
  • Page 33 Fault * Controller List includes: Decision-Makerr 3+, 550, 3000, 3500, 6000, 8000, APM802, or KPC 1000. [ ATS List includes: None, MPACr 750, MPACr 1000, MPACr 1200, or MPACr 1500. ] Annunciator List includes: None, RSA 1000, RSA II, or RSA III.
  • Page 34 Identity addresses based on the range of 1--247. In addition, each field creates addresses for each of the RSA III The identity field provides the user read only information slaves. Up to five slaves can be driven by one RSA III including the Firmware (Software) Version.
  • Page 35 Connection Type Controller Step Operation Manual Other Information EPS Supplying Load ATS emergency aux. contact connections Remote APM802 6.10 TP--7070 Wiring diagram for the respective generator (Generator Set) (Local) hardwired Decision-Makerr 3+ TP-6161 (Industrial) or TP-6441 Wiring diagram for the respective generator...
  • Page 36 Figure 57 RSA III Wiring Diagram GM62554A-J TT-1625 7/17...
  • Page 37 Figure 58 RSA III Wiring Diagram GM62554B-J TT-1625 7/17...
  • Page 38 Figure 59 RSA III Wiring Diagram GM62554C-J TT-1625 7/17...
  • Page 39 Figure 60 RSA III Wiring Diagram GM62554D-J TT-1625 7/17...
  • Page 40 Figure 61 RSA III Wiring Diagram GM62554E-J TT-1625 7/17...
  • Page 41 Figure 62 RSA III Wiring Diagram GM62554F-J TT-1625 7/17...
  • Page 42 Figure 63 RSA III Wiring Diagram GM62554G-J TT-1625 7/17...
  • Page 43 Figure 64 RSA III Interconnection Diagram ADV-6990A-H TT-1625 7/17...
  • Page 44 Figure 65 RSA III Interconnection Diagram ADV-6990B-H TT-1625 7/17...
  • Page 45 Parts List Remote Serial Annunciator Kits and Communication Module Kit Remote Serial Annunciator Kits GM91356 Decision-Makerr 3+ RSA Kits with communication module Standard RSA Kits KPC 1000 RSA Kits -KP1, -KP2, -KP3, -S2: -S4: -S5: -S6: -S7: -S1: -S3: -S8: -S9: No ATS One ATS...
  • Page 46 Notes TT-1625 7/17...
  • Page 47 Notes TT-1625 7/17...
  • Page 48 Singapore 619159 KOHLERPower.com Phone (65) 6264-6422, Fax (65) 6264-6455 Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohlerr generator set distributor for availability.

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