Kohler Power Systems GM49279-KP1 User manual

INSTALLATION INSTRUCTIONS
TT-1443 9
/
07a
Original Issue Date: 7/06
Model: Model K/S and Model K1/S1 Automatic Transfer Switches
Market: ATS
Subject: Remote Annunciator Kits GM49279-KP1, GM49279-KP1S,
GM49280-KP1, GM49280-KP1S, GM52650-KP1 and GM52650-KP1S
Introduction
The Remote Annunciator allows remote monitoring and
limited control of up to 4 transfer switches connected in
an RS-485 network up to 1220 m (4000 ft.) away.
Transfer switches equipped with MPACt1000,
DXPowert1000, MPACt1500, or DXPowert1500
controls can be connected to the remote annunciator.
Figure 1 shows the remote annunciator. Remote
annunciator features include:
D5.7-inch industrial-grade 256-color touch screen
DAudible alarm
DReal-time clock with battery back-up
DPassword-protected setup screen
DIndividual status and detail screens for each ATS:
DSwitch position
DSource availability
DFault conditions
DVoltages for all sources
DFrequencies for all sources
DTime delay identification
DTime delay time remaining display
DGenerator set fault indication
DRemote control features:
DBegin test (password-protected)
DEnd time delay
DEnd test
DAC or DC powered: 100--240 VAC/60 Hz or
24 VDC
DRemote mounting up to 1220 m (4000 ft.) away
DModbusrcommunication through RS-485
connections
The annunciator can be mounted in a
manufacturer-supplied NEMA 4 enclosure, mounted
into a customer-supplied enclosure, or flush-mounted
using a manufacturer-supplied mounting plate. See
Figure 2.
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.
Figure 1 Remote Annunciator
Kit Number Description
GM49279-KP1/KP1S Includes NEMA 4 enclosure
GM49280-KP1/KP1S Includes mounting plate
GM52650-KP1/KP1S Includes NEMA 4 enclosure and
mounting plate
Figure 2 Kits

2 TT-1443 9/07
Notes for Model K and Model S Transfer Switches
Model K/S transfer switches equipped with Series 1000
controllers must have application software version 1.21
or higher to communicate with the Remote Annunciator.
An authorized distributor/dealer can load the latest
version of application software onto the ATS controller.
A personal computer running the ATS Setup Program is
required to configure the communication settings for
each Model K/S ATS. The Setup Program is also
needed to assign a programmable input if the generator
set fault display option is used.
The Remote Annunciator serves as a ModbusrMaster
device in the network. Only one annunciator can be
connected to the ATS or ATS network. The annunciator
and connected transfer switches cannot be connected
to any other Modbusrnetwork.
Notes for Model K1/S1 Transfer Switches
All Model K1/S1 transfer switches equipped with series
1500 controls can communicate with the remote
annunciator. The transfer switch can be configured for
communication with the annunciator using the user
interface on the transfer switch controller.
Use a personal computer running Monitor III software to
assign a unique designation to each transfer switch and
to enter load descriptions.
Note: The transfer switch designations and load
descriptions are not essential to annunciator
operation. However, if more than one ATS is
connected, transfer switch identification on the
annunciator screen will be difficult without these
descriptions. See Figure 19 and Figure 24 for
examples.
The Remote Annunciator serves as a ModbusrMaster
device in the network. Model K1/S1 transfer switches
are equipped with two (2) Modbus ports, which allow
connection of the transfer switch to two (2) Modbus
networks.
Modbus is a registered trademark of Schneider Electric.
Safety Precautions
Observe the following safety precautions while installing
the kit.
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 connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
DANGER

TT-1443 9/07 3
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Making line or auxiliary connections. Hazardous voltage
can cause severe injury or death. To prevent electrical
shock deenergize the normal power source before making any
line or auxiliary connections.
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
NOTICE
Electrostatic discharge damage. Electrostatic discharge
(ESD) damages electronic circuit boards. Prevent
electrostatic discharge damage by wearing an approved
grounding wrist strap when handling electronic circuit boards
or integrated circuits. An approved grounding wrist strap
provides a high resistance (about 1 megohm), not a direct
short, to ground.
1 Installation Procedure
Choose the annunciator location so that the total cable
length to connect all transfer switches in the ATS
network and the remote annunciator is no more than
1220 m (4000 ft.).
Note: The maximum cable length for RS-485 networks
is 1220 m (4000 ft.).
Be sure that the mounting structure can support the
weight of the annunciator assembly. The annunciator
weights are shown below.
Description Weight
Assembly with NEMA 4 enclosure 4.2kg (9lb.)
Flush-mounted assembly with
mounting plate 1.4kg(3 lb.)
Figure 3 Weights
1.1 Prepare the annunciator enclosure, if
used.
For annunciators installed in an enclosure, drill separate
holes in the top, bottom, or left side of the enclosure for
the power and signal cables. Remove burrs and metal
chips. Use separate conduit for power and signal
connections.
Note: The enclosures provided with the kits meet
NEMA 4 requirements. Use conduit hubs as
required to meet the desired NEMA rating (up to
NEMA 4) for the application.

4 TT-1443 9/07
1.2 Connect power and communication
cables to the annunciator.
Use shielded twisted-pair cable, Belden #9841 or
equivalent, to connect the annunciator to the transfer
switches. The total cable length must be no more than
1220 m (4000 ft.).
Note: Use separate conduit for power and
communication cables.
1. Connect the shielded twisted-pair cable to
terminals 1, 5, and 6 on the annunciator’s RS-485
connector. See Figure 4 for the connections.
2. Plug the RS-485 connector into the annunciator’s
9-pin communication port (COM1). See Figure 4.
1. Connect VAC to power supply as shown
2. RS-485 connector
1 2
Figure 4 Annunciator Connections
3. Disconnect power to the annunciator power source
by opening the line circuit breaker or switch.
4. Connect AC or DC power leads to the annunciator.
See Figure 4. Choose step a or b below:
a. Connect AC power leads to the annunciator
power supply. The power supply accepts
100--240 VAC/60Hz input power. Use #12--#24
AWG cable for the power connections. Tighten
the connections to 0.5 Nm (4 in. lb.). The
power supply terminals are labeled; OR
b. Connect power leads for 24 VDC to the
terminals on the back of the annunciator. The
terminals are labeled.
Note: Do not connect power to the annunciator at this
time.

TT-1443 9/07 5
1.3 Prepare the mounting surface.
NEMA 4 Enclosure. The annunciator enclosure has
mounting tabs with 8 mm (0.3 in.) mounting holes. See
Figure 5. Use the dimensions shown in Figure 5 or use
the enclosure as a template to mark and drill holes in the
mounting surface.
ADV-6827
Dimensions are shown in mm [in.]
Figure 5 Dimension Drawing, NEMA 4 Enclosure, Kit Part Numbers GM49279-KP1 and GM49279-KP1S

6 TT-1443 9/07
Mounting plate. See Figure 6. Select a
customer-supplied box or other mounting surface to
attach the annunciator and mounting plate. Choose
step 1 or 2 below:
1. Use a customer-supplied enclosure. The
mounting plate is designed to be used with a
Hoffman enclosure part number A-SE12X10X6,
A-SG12X10X6, or equivalent; OR
2. Select a location for the mounting plate that
provides adequate clearance and depth for the
annunciator, power supply, and connectors. See
Figure 6. Use the dimensions shown in Figure 6 or
use the mounting plate as a template to mark and
drill holes in the mounting surface. Remove burrs
and metal chips.
Dimensions are shown in mm [in.]
Figure 6 Dimension Drawing, Flush-Mounted Annunciator, Kit Part Numbers GM49280-KP1 and GM49280-KP1S

TT-1443 9/07 7
1.4 Prevent the generator set from starting.
1. Place the generator set master switch in the OFF
position.
2. Disconnect the power to the battery charger, if
equipped.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
1.5 Disconnect power to the transfer
switches.
1. Disconnect power to all transfer switches by
opening the Normal and Emergency source circuit
breakers or switches.
2. Open the ATS enclosure door to access the ATS
controller.
1.6 Connect the generator set fault output
to ATS input terminals (optional).
The annunciator can display a generator set fault, if
desired. One fault output from the generator set
controller can be connected to the ATS controller’s input
terminals on terminal block TB1 or to an input/output
module.
1. Refer to the generator set controller
documentation to identify the normally open output
contacts for the selected fault.
2. Use #12--24 AWG cable to connect the generator
set output to the ATS input terminal. Choose step a
or b, below:
a. Connect to programmable input 1 or
programmable input 2 on TB1 on the ATS
controller’s main logic board. See Figure 7 or
Figure 8.
b. Connect to an available input terminal on an
input/output (I/O) module. See Figure 9
through Figure 11. I/O modules are optional
equipment. Refer to the instructions provided
with the I/O module kit or the transfer switch
operation and installation manual.
GM21364
1. Terminal strip TB1 location (controller cover removed)
2. Serial port connection (P6) for PC
3. Input connections (TB1)
1
3
GM22366
2
TB1 Connection Detail
Figure 7 Series 1000 Input Connections

8 TT-1443 9/07
1. Input/output terminal strip TB1
2. Serial ports 0 and 1 (RS-485 connections) TB2
3. Ethernet port (RJ-45 connector) P13
4. Connect generator set output to input 1 or input 2
GM46733
Logic
Board
Power
Board
--
--
1
Input 1A
Input 1B Input 2A
Input 2B
Output 1 NC
Output 1 C
Output 1 NO
Output 2 NC
Output 2 C
Output 2 NO
Logic Board Input/Output Connections, TB1
NC = normally closed
NO = normally open
C = common
12
6
1
7
2
3
1
44
Figure 8 Series 1500 Input Connections
GM21115a
1. Input connections
1
TB2
1
6
P2
-- -- O P E N -- --
321
DIAGNOSTIC
SW1
IN1+
IN1--
DIGITAL
IN2+
IN2--
RDO1 RDO2 RDO3
RDO5 RDO6
RDO4
RELAY OUTPUT
INPUT
LED1
6
P1
TB1
Figure 9 Series 1000 I/O Module Input Connections
1. Input connector
GM41093
1
Figure 10 Series 1500 Standard I/O Module

TT-1443 9/07 9
1. Input connector
1
GM42186
Figure 11 Series 1500 High-Power I/O Module
1.7 Connect transfer switches and
annunciator in an RS-485 network.
Use separate conduit for power and signal connections.
Use shielded twisted-pair cable, Belden #9841 or
equivalent, to connect the annunciator and the transfer
switches. The total cable length must be no more than
1220 m (4000 ft.).
1. Connect up to four transfer switches to the
annunciator. Connect to the RS-485 terminals on
the terminal strip on the transfer switch controller’s
main logic board. See Figure 12 for the
Series 1000 or Figure 13 for the Series 1500.
Note: For Series 1500 units, record the port
number (0 or 1) connected to the
annunciator for each transfer switch. The
port number is required for controller setup
later in this procedure.
2. Connect a 121 ohm terminating resistor on the last
device in the network. If there is only one device, a
terminating resistor may be required depending on
the cable distance and the communication speed.
Long cables and higher speeds will increase the
need for a terminating resistor.
3. Connect the transfer switch to a personal computer
at this time. For Series 1000 controls, the Setup
Program will be needed to set up the transfer
switch communication settings and assign transfer
switch and load descriptions. For Series 1500
controls, Monitor III software will be needed to
assign transfer switch and load descriptions.
a. For the Series 1000, connect the PC to the
RS-232 serial port. See Figure 7.
b. For the Series 1500, connect the PC in one of
two ways:
Connect to the local ethernet through the RJ-45
connector on the ATS controller, or
Connect to the second serial port on the ATS
controller. Use an RS-485-to-RS-232
converter and/or a USB-to-serial port converter
to connect to the PC as needed. Record the
port number (0 or 1) for use during the
communication setup later in this procedure.
See Figure 8 and Figure 13.

10 TT-1443 9/07
ATS 1
TT1443
LAST ATS
Connect A to A, B to B,
and GND to GND (cable
shield) between devices
Annunciator-to-ATS Connections:
Terminal 1 to B (TB1-11)
Terminal 5 to GND (TB1-10)
Terminal 6 to A (TB1-12)
DConnect up to four (4) transfer switches to one annunciator.
DUse twisted-pair shielded cable, Belden #9841 or
equivalent, customer-supplied.
DUse a maximum total cable length of 1219.2 m (4000 ft.)
from the annunciator to the last transfer switch.
DA 121 ohm terminating resistor on the last device in the
network is recommended.
DInstall communication conductors in raceways, cables, or
conduit separate from AC power conductors.
Belden #9841
cable
Figure 12 Annunciator and ATS Connections, Series 1000