Kohler OnCue Plus User manual

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INSTALLATION INSTRUCTIONS
Original Issue Date: 6/14
Model: 6--60 kW Generator Sets with RDC2/DC2, VSC, or RDC/DC Controller
Market: Residential/Light Commercial
Subject: OnCuerPlus Wireless Kits GM62465-KP3-QS and GM81385-KP3-QS
Introduction
The OnCuerPlus Wireless Kit allows wireless
connection of residential/light commercial generator
sets to the owner’s wireless router for Internet access.
Use this kit to connect the generator set to the Internet
for the KohlerrOnCuerPlus Generator Management
System.
The kit uses a wireless access point (AP) to connect the
generator set to the Internet without running a cable
from the owner’s router to the generator set. The
wireless AP is installed inside the generator enclosure
and powered by the generator’s engine starting battery.
These instructions explain installation and setup of the
wireless AP.
The VHB tape provided with the kit allows installation of
the kit components without drilling additional holes or
using special tools. The ambient temperature must be
warmer than 0_C(32_F) at the time of installation. Once
installed, the tape is rated for --35 to 110_C
(--31 to 230_F).
See Figure 1 to identify the correct OnCue Plus wireless
kit for your generator model. See Figure 2 for the
wireless access point (tape not shown).
Special Equipment
The following items are required for installation and
setup.
DWireless router for Internet connection, customer-
provided
DThe customer’s wireless network security properties
and password are required. Step 11 of these
instructions explains how to obtain this information.
DLaptop computer (for initial setup only)
DNetwork cable for temporary connection of laptop PC
to the kit (for initial setup only)
Generator Model Wireless Kit Number
14/20RES GM62465-KP3-QS
6VSG
14/20RESA
38/48/60RCL
GM81385-KP3-QS
Figure 1 Kits and Models
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1. Wireless access point GM91273-1
2. Cable 357477
3. LAN port
4. Power over Ethernet (PoE) box GM91273-3
5. Power cable provided with kit (see Figure 4)
6. PoE port
Note: VHB mounting tape is not shown in this photo.
41
2
6
SeeFigure4.
3
Figure 2 GM91273 Wireless Access Point
Assembly

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Safety Precautions
Observe the following safety precautions while
performing this procedure.
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.
WARNING
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.
FCC Interference Statement
This equipment has been tested and found to comply
with the limits for a Class B digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful
interference in a residential installation. This equipment
generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with
these instructions, may cause harmful interference to
radio communications. However, there is no guarantee
that interference will not occur in a particular installation.
If this equipment does cause harmful interference to
radio or television reception, which can be identified by
turning the equipment off and on, the user is encouraged
to try to correct the interference by one of the following
measures:
DReorient or relocate the receiving antenna.
DIncrease the separation between the equipment and
the receiver.
DConnect the equipment into an outlet on a different
circuit from that to which the receiver is connected.
DConsult the dealer or an experienced radio/TV
technician for help.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions. (1)
This device may not cause harmful interference, and (2)
this device must accept any interference received,
including interference that may cause undesired
operation.
FCC Caution: Any changes or modifications not
expressly approved by the party responsible for
compliance could void the user’s authority to operate
this equipment.
FCC Radiation Exposure Statement
This equipment complies with FCC radiation exposure
limits set forth for an uncontrolled environment. To avoid
the possibility of exceeding radio frequency exposure
limits, you shall keep a distance of at least 100 cm
(39.4 in.) between you and the antenna of the installed
equipment. This transmitter must not be co-located or
operating in conjunction with any other antenna or
transmitter.
The availability of some specific channels and/or
operating frequency bands are country-dependent and
are firmware-programmed at the factory to match the
intended destination. The firmware setting is not
accessible by the end user.

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Installation Procedure
The wireless access point hardware must be installed
inside the generator set enclosure. See Figure 5,
Figure 6, or Figure 7 for the recommended location on
your generator set model.
The ambient temperature must be warmer than 0_C
(32_F) at the time of installation. Once installed, the
VHB mounting tape is rated for --35 to 110_C
(--31 to 230_F).
1. Disable the generator set to prevent
accidental starting.
1.1 Press the OFF button on the generator set
controller.
1.2 Disconnect the utility power to the generator set.
1.3 Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
2. Remove enclosure doors and/or panels
as necessary to access the air intake
area or the engine compartment (RCL
models).
3. Install the wireless access point and
Power over Ethernet (PoE) box.
3.1 See Figure 5, Figure 6, or Figure 7 for the
recommended mounting locations on your
generator set model. Make sure the surfaces
where the PoE box and access point will be
mounted are clean and dry.
3.2 Cut one piece of VHB tape approximately 1 inch
long. Use the tape to attach the Power over
Ethernet (PoE) box GM91273-3 inside the
enclosure as shown for your model in Figure 5,
Figure 6, or Figure 7.
3.3 Cut two or three pieces of the VHB tape
GM91273-5 (provided in the kit) approximately
2.5 inches long. Use the VHB tape to attach
wireless access point GM91273-1 to the inside
of the enclosure as shown for your model in
Figure 5, Figure 6, or Figure 7.
3.4 Connect cable 357477 to the port on the bottom
of the wireless access point. Connect the other
end of the cable to the PoE port on the PoE box.
SeeFigure2.
3.5 Connect the power cable to the DC port on the
PoE box. See Figure 2.
3.6 Connect the ring terminals on the power cable to
the generator set battery terminals. Follow the
polarity in Figure 3. See Figure 4 for an
illustration of the power cable.
Cable Battery Terminal
Black Positive (+)
Black and White Negative (--)
Figure 3 Power Cable Battery Connections
1
GM91273
1. Connect to PoE box DC port
2. Connect ring terminals to generator set battery 2
NOT TO SCALE
Figure 4 Power Cord

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Figure 5 Wireless AP Assembly Drawing GM81385, Sheet 1 of 3

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Figure 6 Wireless AP Assembly Drawing GM81385, Sheet 2 of 3

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Figure 7 Wireless AP Assembly Drawing GM81385, Sheet 3 of 3

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Setup Procedure
A laptop computer with access to the Internet is required
to set up the wireless access point. Once setup is
complete, the computer is no longer needed.
Note: The screen shots shown in this document were
created using Windowsr7. Screens and
instructions may vary for different computer
operating systems.
4. Connect the wireless access point to the
computer.
4.1 Check that the power and network cables are
connected to the wireless access point and PoE
box as described in step 3.
4.2 Use a customer-provided network cable to
attach a laptop computer to the LAN port on on
thePoEBox. SeeFigure2.
5. Change the IP address of your
WindowsrPC to connect to the device.
Note: For Macrcomputers, go to step 6.
5.1 Click on the the Windows start menu icon in the
lower left corner of your screen. See Figure 8.
5.2 Type “network connections” into the Search
programs and files box.
5.3 Press Enter or click on View network
connections.
5.4 Click on Local Area Connection.
Figure 8 Selecting the Local Area Network
Connection
5.5 Select Internet Protocol Version 4. See
Figure 9.
5.6 Click Properties.
Figure 9 Selecting Internet Protocol Version 4
5.7 Click on Use the following IP address. See
Figure 10.
5.8 Change the IP address to 192.168.1.5 and
Subnet mask to 255.255.255.0.
5.9 Click OK.
5.10 Go to step 7.
Figure 10 Entering the IP Address and Subnet Mask
Windows and Internet Explorer are a registered trademarks of Microsoft Corporation in the United States and/or other countries.
Apple, the Apple logo, and Mac are registered trademarks of Apple Inc., registered in the U.S. and other countries.

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6. Change the IP address of your Macr
computer to connect to the device.
6.1 Click the Applericon.
6.2 Click System Preferences.
6.3 Click the Network icon.
6.4 Click the Ethernet connected icon.
6.5 Change Configure IPv4 to Manually.
6.6 Enter the IP Address 192.168.1.5.
6.7 Change the Subnet Mask to 255.255.255.0.
6.8 Enter Router address 192.168.0.1.
6.9 Click Apply.
6.10 Proceed to step 7.
7. Enter the gateway to the wireless access
point.
7.1 Open your Internet browser (Internet Explorerr
or other browser).
7.2 Type 192.168.1.222 in the address bar. See
Figure 11.
7.3 Press Enter. The window shown in Figure 12
opens.
Figure 11 Enter Gateway Address in Internet
Explorer
8. Sign into the wireless access point.
8.1 Enter “admin” for Name.
8.2 Enter “password” for Password.
8.3 Press Login.
password
Figure 12 Signing in to the Access Point
9. Configure the wireless access point.
9.1 Click the System tab. See Figure 13.
9.2 Under Basic Settings: change Network Mode to
Bridge.
9.3 Click the Apply button to save the settings.
Note: If you do not click Apply, the settings will
not be saved.
Figure 13 System Basic Settings
9.4 Click Wireless tab. See Figure 14.
9.5 Under Basic Settings change:
9.5.1 Wireless Mode to Wireless Client.
9.5.2 802.11 Mode to 802.11B/G/N.
9.5.3 Channel Mode to 20 MHz.
Customer’s Wireless
Figure 14 Wireless Basic Settings

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9.6 Choose the type of antenna.
Note: If you are using an external antenna,
make sure that you connect the external
antenna to the radio before you enable it.
9.6.1 If you are not adding an external
antenna, choose Internal antenna.
9.6.2 If you are adding an external antenna,
choose External antenna and change
Antenna Gain to 8 dB.
9.7 Click the Apply button to save the settings.
9.8 Click Site Survey. See Figure 15.
Customer’s Wireless
Figure 15 Select Site Survey
10. Select the customer’s wireless network.
10.1 Under Site Survey, select the customer’s
wireless network name (shown as Customer
Wireless in this document). See Figure 16.
10.2 Click the Apply button to save the settings.
Note: The name of the customer’s
wireless network appears here.
Figure 16 Select the Customer’s Wireless Network
11. Connect to the customer’s wireless
network.
11.1 Click on the network icon in the lower right corner
of the screen. See Figure 17.
11.2 Click on the customer’s wireless network
(shown here as Customer_Wireless).
11.3 Click Connect.
11.4 Type in Security Key/Password when prompted.
Note: If the network is not password protected,
proceed to step 13, Enter Wireless
Profile Settings.
If the password is not known, use a
computer that is connected to the
customer’s wireless network to check
the security settings. (The computer
must be connected wirelessly.) Follow
the instructions in step 12.
Figure 17 Connect to Customer’s Wireless Network

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12. Obtain wireless security settings (if
necessary).
12.1 Click on the Wireless icon in the lower right
corner of screen. See Figure 18.
12.2 Right click on customer’s wireless network
name (shown here as Customer_Wireless).
12.3 Click on Properties.
Figure 18 Obtain Wireless Security Settings
12.4 Click on Show characters to see the required
security settings for the wireless access point.
See Figure 19.
Note: PSK=Personal
Figure 19 Security Settings
13. Enter the wireless profile settings.
13.1 Click on the Wireless tab.
13.2 Under Profile Settings: Wireless Network Name
should be the customer’s wireless.
13.3 Fill in Security Settings from step 12:
13.3.1 Network Authentication.
Note: PSK=Personal
13.3.2 Data Encryption.
13.3.3 WPA passphrase.
13.4 Click the Apply button to save the settings.
Figure 20 Enter the Security Settings

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14. Test the connection (WindowsrPC).
for Mac computer, go to step 15.
14.1 Click on the Windows Start icon in the lower left
corner of the screen. See Figure 21.
14.2 Type “network connections” in the Search
programs and files window.
14.3 Press Enter or click on View network
connections.
Figure 21 Search for Network Connections
14.4 Click on the Local Area Connection. See
Figure 22.
Figure 22 Select Local Area Connection
14.5 Select Internet Protocol Version 4. See
Figure 23.
14.6 Click on Properties.
Figure 23 Select Internet Protocol Version 4
14.7 Select Obtain an IP address automatically. See
Figure 24.
14.8 Click OK.
14.9 Go to step 16.
Figure 24 Obtain an IP Address Automatically

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15. Test the connection (Macrcomputer).
15.1 Click on the Applericon.
15.2 Click on System Preferences.
15.3 Click on the Network icon.
15.4 Click on the Ethernet connected icon. Verify that
Ethernet is in the connected state, indicated by a
green dot.
15.5 Change Configure IPv4 to Using DHCP.
15.6 Click Apply.
15.7 Proceed to step 16.
16. Disconnect from wireless.
16.1 Click on wireless symbol.
16.2 Click on the customer’s wireless.
16.3 Click Disconnect. The wireless symbol should
change from to and you should be able to
get onto the Internet. Go to KOHLERPower.com
or another known website to verify the Internet
connection.
16.4 Disconnect the laptop from the wireless access
point.
Figure 25 Disconnect from Wireless
17. Connect the LAN port on the PoE box to
the generator set’s network cable.
A network cable is provided on the generator set and
factory-connected to the generator controller. See
Figure 5, Figure 6, or Figure 7 for the PoE box and
network cable locations on the generator. See Figure 2
for the location of the LAN port on the PoE box.
18. Return the generator set to service.
18.1 Reconnect the generator set engine starting
battery, negative (--) lead last.
18.2 Replace the air intake panel on the enclosure (if
removed).
18.3 Reconnect utility power to the generator set.
18.4 Set the time, date, and exercise on the controller.
See the generator set Operation Manual for
instructions, if necessary.
18.5 Press AUTO on the generator set controller.

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Troubleshooting
If the device loses connection to your router and does
not reconnect on its own, disconnect and reconnect the
power cable at the DC port on the PoE box. See
Figure 26. Allow up to five minutes for the generator to
reconnect to OnCue.
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1. Disconnect power by unplugging this cable
(connects to
generator battery)
Figure 26 Disconnect and Reconnect Power to the
PoE Box
If the generator reconnects to OnCue after
disconnecting and reconnecting power, setting the
Watchdog feature may prevent similar problems in the
future. Follow the instructions in this section to set the
Watchdog feature for the wireless access point.
This procedure requires the default gateway IP address
for the customer’s router. Example: 192.168.1.1 is a
very common default gateway used by router
manufacturers. To find the default gateway IP address:
DCheck for a label on the router or consult the router
manufacturer’s instruction manual or website.
DAlternatively, use a computer connected to the
customer’s wireless network to find the default
gateway IP address. The procedure varies for
different operating systems; search the Internet for
“finding default gateway IP address via a personal
computer” to find instructions.
Ping Interval and Failure Count
The OnCue Plus server is set to notify a customer if a
device has lost connection for 1 hour or more. The ping
interval multiplied by the failure count determines the
time before the wireless access point resets. Setting the
ping interval and the failure count to reboot combination
to be less than 1 hour is recommended. For example,
set the ping interval to 300 seconds (5 minutes) and the
failure count to 9 for reset time of 45 minutes (5 minutes
x 9 intervals). The wireless device would reset after a
period of 45 minutes has elapsed with no response from
the router.
19. Setting the Watchdog
19.1 Follow steps 4 through 8 to connect a laptop
computer to the wireless access point.
19.2 Click on the Tools tab. See Figure 27.
19.3 Click on Ping Watchdog.
19.4 Select Enable Ping Watchdog.
19.5 Type the Default Gateway IP address into the IP
Address to Ping.
Note: The customer’s IP Address may be
different than the address shown.
Figure 27 Ping Watchdog

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20. To confirm proper operation of the
Watchdog feature, follow the steps
below.
Note: These are temporary settings for this test only.
Do not leave this device with these test settings.
20.1 Set the ping interval to 60 seconds.
20.2 Set the failure count to reboot to 1.
20.3 Click Apply.
20.4 After approximately 1 minute, confirm that the
power indicator on the side of the access point
stays green and the signal indicator is on and
solid. This confirms that the ping to the router
was successful.
If the power indicator blinks amber after
approximately 1 minute, this indicates the device
did not see a response from the router and the
watchdog reset the controller. Confirm the
default gateway IP address is correct. If so,
confirm that the configuration settings from step
9 are correct.
21. After confirming that the device is not
resetting, change the Watchdog settings
as described below:
21.1 Set the Ping Interval to 300 seconds.
21.2 Set the Failure Count to Reboot to 9.
21.3 Click Apply.
21.4 Follow steps 16 through 18 to disconnect the
laptop and return the system to service.
Device Reset Button
Note: Do not press the reset button on the wireless
access point.
Pressing the reset button will change the IP address of
the access point to 192.168.1.1 and may result in a loss
of Internet access.
The reset button is recessed and difficult to press
accidentally. If the reset button was pressed, follow
these instructions to reset the IP address to
192.168.1.222.
22. Procedure to change the IP address, if
necessary.
22.1 Follow steps 4 through 8 to connect a laptop
computer to the wireless access point. Use the
IP address 192.168.1.1.
22.2 Click on System. See Figure 28.
22.3 Click on TCP/IP Settings.
22.4 Select Use Fixed IP Address.
22.5 Change the IP address to 192.168.1.222.
22.6 Click on Apply.
22.7 Follow steps 16 through 18 to disconnect the
laptop and return the system to service.
Figure 28 Changing the IP Address

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Additional Information
LED Operation
Power
Green On = System On
Green Off = System Off
Amber Blinking = WLAN Activity
LAN
Off = No Ethernet
On = Connection Established
Blinking = Sending, Receiving
WLAN
(AP Mode)
Off = WLAN Disabled
On = WLAN Enabled
Blinking = WLAN Activity
WLAN
(Client Mode)
Off = WLAN Disabled
Green Blinking = Good Connection
Yellow blinking = Acceptable Quality
Red Blinking = Poor Connection
Internal Antenna Electrical Specifications
Antenna shape Patch array
RF frequency band 2.4 -- 2.5 GHz
Power handling 2W
Impedance 50 Ohms
VSWR Less than 2.0
Polarization Linear (vertical)
Antenna Gain Peak gain 2.45 GHz 8.45 dBi
Vertical HPBW 113_
Horizontal HPBW 39_

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Parts Lists
OnCue Wireless, RDC/DC Controllers
Kit: GM62465-KP3-QS
Qty. Description Part Number
1OnCue Plus Welcome Letter G18-246
1OnCue App Quick Start Guide G18-247
1S/S WiFi Kit for RDC2, Res/Coml G6-137
1 Screw, Plastic Tapping, 6-19 x 0.375 GM23307
1PCB Assy, Ethernet Option GM60385-1
1Header, PCB Pin GM60410
1Kit, Wireless Access Point GM91273
1Cable, 3 ft. RJ-45 357477
1Access Point, Wireless GM91273-1
1Port, Power over Ethernet GM91273-3
1Tape, VHB 3/4”, 10in Long GM91273-5
1O/M OnCue Plus Res/Coml TP-6928
1 TT OnCue Ethernet Board
14/20RES/L
TT-1566
1Install Guide WiFi Kit Res/Coml TT-1618
OnCue Wireless, RDC2/DC2/VSG
Kit: GM81385-KP3-QS
Qty. Description Part Number
1OnCue Plus Welcome Letter G18-246
1OnCue App Quick Start Guide G18-247
1S/S WiFi Kit for RDC2, Res/Coml G6-137
1Decal, OnCue Activation Code GM81386
1Cable, 3 ft. RJ-45 357477
1Kit, Wireless Access Point GM91273
1Access Point, Wireless GM91273-1
1Port, Power over Ethernet GM91273-3
1Tape, VHB 3/4”, 10in Long GM91273-5
1O/M OnCue Plus Res/Coml TP-6928
1Install Guide WiFi Kit Res/Coml TT-1618
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
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 Kohlerrgenerator
set distributor for availability.
2014 by Kohler Co. All rights reserved.