Kohler Power Systems KD Series Bedienungsanleitung

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.

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.

2TT-1719 12/16

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

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.

4TT-1719 12/16

KOHLER CO., Kohler, Wisconsin 53044 USA

Phone 920-457-4441, Fax 920-459-1646

For the nearest sales and service outlet in the

US and Canada, phone 1-800-544-2444

KOHLERPower.com

Kohler Power Systems

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 design or specifications without notice and without any

obligation or liability whatsoever. Contact your local Kohlerrgenerator

set distributor for availability.

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