Kohler Power Systems KD Series User manual

TT-1719 12/16a
INSTALLATION INSTRUCTIONS
Original Issue Date: 12/16
Model: KD Series Generator Sets with APM802 Controller
Market: Industrial
Subject: Remote Emergency Stop Kits, 11101000201-KP1
Introduction
TP-6200
Figure 1 Remote Emergency Stop Switch
The emergency stop kit allows immediate shutdown of
the generator set from a remote location. Mount the
emergency stop switch(es) in a location easily
accessible by operating personnel at a normal
workstation. See Figure 1.
If the emergency stop switch is activated, the controller
shuts down the unit, places the controller in
Out-of-Service mode, and displays an Emergency
Push Button Engaged Fault on the HMI. The generator
set cannot be restarted until the emergency stop
switch(es) is reset by replacing the glass piece and
clearing the fault on the controller.
Emergency Stop Kit Connection
(with multiple switches)
Emergency Stop
Kit Connection
(with single switch)
TB10
terminal
block
Remove jumper before
installing kit.
1
2
1
2
1
2
1
2
K10
K10 relay
Local Emergency Stop
Figure 2 Terminal Block Connections
Connect as many emergency stop switches as
required; however, connect multiple switches in series
so the system functions correctly. The emergency stop
switch is connected to terminal block 10, TB10-1 and 2.
See Figure 2. Remove the jumper from terminals
TB10-1 and 2 before installing the kit. When the
emergency stop switch is activated, contacts in the
switch open to deenergize the K10 relay and shut down
the generator set.

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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 equipment connected to the set, disable the
generator set as follows: (1) Shut down the generator set. (2)
Place the controller in Out of Service mode. (3) Press the
emergency stop button. (4) Disconnect the power to the
battery charger, if equipped. (5) 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.
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Installation Procedure
1. Before working on the generator set or connected
equipment, disable the generator set. Refer to the
safety precautions for preventing accidental starts
and disabling the generator set.
a. Remove the load from the generator set.
b. Shut down the generator set.
c. Place the generator set controller into
Out-of-Service mode and press the
emergency stop button.
d. Disconnect the power to the battery charger.
e. Remove the battery cables negative (--) lead
first to disable the generator set.
2. To access the terminal block, TB10, remove the
eight screws from the lower compartment cover on
the control panel. See Figure 3.
3. Remove jumper from terminals TB10-1 and 2.
1. Lower compartment
cover
2. TB10
3. 38 mm (1-1/2 in.) holes
1
2
3
Figure 3 Lower Compartment Component Location

TT-1719 12/16 3
4. Verify that the emergency stop switch leads are
from the normally closed contacts. Use an
ohmmeter to perform the continuity test. Use tape
to insulate the normally open contact leads as they
will not be used.
5. Determine the approximate mounting location(s)
for the emergency stop switch(es) and cut two
lengths of 16-gauge (minimum) stranded wire long
enough to connect the controller and switch(es).
Strip one end of each wire length and connect to
switch leads using wire nuts (not supplied).
Connect the two white leads from the switch to the
lead from terminal 1. Connect the two black leads
from the switch to the lead from terminal 2.
6. Mount emergency stop switch(es) in desired
location(s). Use #6 round head wood screws (not
supplied). Use supplied machine screws when
mounting in a single-gang electrical box.
7. Route the stranded wire through the 38 mm
(1-1/2 in.) holes in the back of the control panel to
the terminal strip, TB10. See Figure 3. Cut leads
to length, strip the ends, and connect to terminals
TB10-1 and 2. See Figure 2.
8. Position and secure the lower compartment cover.
9. Check that the generator set is in Out-of-Service
mode.
10. Reconnect the generator set engine starting
battery, negative (--) lead last.
11. Reconnect power to the battery charger.
Resetting Procedure
1. Replace glass rod on emergency stop switch (an
extra piece of glass is supplied with each switch).
2. Reset the fault displayed on the controller human
machine interface (HMI).
3. Place the generator set into Manual mode for local
starting or to AUTO mode for startup by automatic
transfer switch or remote start switch. Refer to the
controller operation manual for controller
operation instructions.
Parts List
Qty. Description Part Number
1Switch, emergency stop A-222654
2Rod, glass* 222655
* Part of A-222654 emergency stop switch. One glass rod is
installed on the switch and an additional replacement glass rod
is located inside the switch. Additional glass rods are available
as a service part.

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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.
2016 by Kohler Co. All rights reserved.