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INSTALLATION AND OPERATION INSTRUCTIONS

TT-1596 3/15d

Original Issue Date: 8/12

Model: 14RESA, 20RESA, and 20RESB

Market: Residential/Light Commercial

Subject:

PowerSynct Automatic Paralleling Module (APM) Kit

GM85144-KP1-QS and Circuit Breaker Kits GM86368-KP1-QS and

GM86369-KP1-QS

Introduction

This document describes the installation and operation

of the PowerSynct Automatic Paralleling Module

(APM) and optional circuit breakers for single-phase

residential generator sets. The APM allows the use of

two Model 14RESA or two 20RESA/20RESB generator

sets in a single-phase paralleling system to supply

power to one building or site.

The APM provides a common connection point for

paralleling generators and permits individual control of

the generator connections, allowing for

synchronization, redundancy, and generator

management.

zab26291

Figure 1 PowerSynct Automatic Paralleling

Module

The following combinations of single-phase

generator sets can be paralleled:

D Two single-phase Model 14RESA generator sets

with the same 110/220, 115/230, 120/240, 220, 230,

or 240 volt configuration

D Two single-phase Model 20RESAs, two 20RESBs, or

one 20RESA and one 20RESB with the same

110/220, 115/230, 120/240, 220, 230, or 240 volt

configuration

Automatic paralleling requires:

D Two single-phase generator sets as shown above.

D RDC2 paralleling firmware RDC2_###_#.bin version

105.4 or higher on each generator set. Download the

paralleling firmware from TechTools.

D One Model RXT automatic transfer switch (ATS)

D One Automatic Paralleling Module (APM) kit

D A personal computer (laptop) with Kohlerr

SiteTecht software version 3.5 or higher is required

for system setup.

D A Load Control Module (LCM), Load Shed kit, or other

load management system is required if one

generator set cannot support the maximum total load.

The LCM or load shed kit is necessary in order to shed

non-critical loads in the event that one generator set

shuts down and the other generator set cannot support

all of the loads. The RXT with the combined

interface/load management board also satisfies this

requirement.

The APM and associated equipment must be installed

by a Kohlerr trained and authorized distributor or dealer.

Summary of content (36 pages)

PAGE 1
TT-1596 3/15d INSTALLATION AND OPERATION INSTRUCTIONS Original Issue Date: Model: Market: Subject: 8/12 14RESA, 20RESA, and 20RESB Residential/Light Commercial PowerSynct Automatic Paralleling Module (APM) Kit GM85144-KP1-QS and Circuit Breaker Kits GM86368-KP1-QS and GM86369-KP1-QS Introduction This document describes the installation and operation of the PowerSynct Automatic Paralleling Module (APM) and optional circuit breakers for single-phase residential generator sets.
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Circuit Breaker Kits Other Accessories If the APM is not installed within sight of the generator sets, local codes may require the installation of circuit breakers near the APM. Circuit breaker kits are available for installation inside the APM enclosure. Other compatible accessories include: Figure 2 shows the circuit breaker kit numbers for the 14RESA, 20RESA, and 20RESB generator sets. Verify that you have the correct kit for your generator set model.
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Related Literature A single-phase paralleling system is made up of the APM module covered by this instruction sheet plus two generator sets and a Model RXT transfer switch. A load control module (LCM), load shed kit, or combined interface/load management board on the RXT is required if one generator set cannot support the maximum total load. An optional PIM and OnCuer Plus monitoring system may also be used with the power system.
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1 Installation Procedure FROM GENERATOR 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. For the generator sets, transfer switch, LCM or load shed kit, and other accessories, refer to the installation instructions provided with each component during this procedure. Dot on CT, this side 1.
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Figure 7 TT-1596 3/15 RXT Load Leads Voltage sensing Conduit * See wiring diagrams in Figure 33 and Figure 34 for connection details. Load Leads Voltage sensing CT RDC2 Communication cable (RBUS) * Route all wiring in conduit. Route low-voltage communication leads in separate conduit from the load leads. [ Connect both generator sets to the Internet through the customer’s Ethernet router/modem. ] Load control is required if one generator set cannot support the maximum total load.
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5. Install the adaptor harnesses for voltage sensing connection: 1.2 Install the automatic paralleling module (APM). a. Disconnect the generator set harness at P2 on the back of the RDC2 controller. See Figure 6. b. Connect the adaptor harness to P2 on the RDC2 controller. See Figure 6 and Figure 8. c. Connect the other end of the adaptor harness to the generator set harness. d. Repeat for the second generator set. 6. The adaptor harness connected in step 5 contains a voltage sensing lead (V9).
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1.3 Install the circuit breaker kit, if required. 11. install circuit breaker mounting bracket GM85151 onto the back wall of the APM enclosure: Note: The circuit breaker kit may be required if the APM is not installed within sight of the generator sets. Ensure that the installation complies with the NEC and local codes. a. Remove the 4 existing screws X-67-133 and 8 existing washers X-25-36 from the back wall of the enclosure. See Figure 9. Save the screws; the washers can be discarded.
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For the 20RESA or 20RESB, 100 amp circuit breakers: 12. Mount two circuit breakers onto the bracket. c. Use 2 X-67-132 thread-forming screws to attach each circuit breaker to the mounting bracket. See Figure 11. For the 14RESA, 70 amp circuit breakers: a. Use 4 X-67-132 thread-forming screws and 4 X-400-145 spacers for each circuit breaker. Install the spacers between the circuit breaker mounting tabs and the bracket. See Figure 10. b.
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13. See Figure 9 and Figure 12. Carefully remove the knockouts for the circuit breakers in the inner cover of the enclosure: a. Remove the larger portion on the left side of each knockout for the 70 amp breakers (14RESA) OR b. Remove both portions of the knockout for the 100 amp breakers (20RESA/20RESB). 1 2 GM85148 Figure 13 Decals provided with APM GM85144 1. Remove only this portion for 70 amp breakers 2. Remove both portions for 100 amp breakers Figure 12 Circuit Breaker Knockouts 14.
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2 Connections After the physical installation of the paralleling system components, make the electrical connections described in this section. 1. Press the OFF buttons on both generator set controllers. 2. Turn off the AC power that supplies the battery charger on both generator sets. 3. Disconnect the generator set engine starting battery(ies), negative (--) lead first. 2.1 Voltage Sensing 4.
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2.2 RBUS Communication Connections Note: The RBUS communication wiring to the APM must be connected directly to the generator sets as shown in Figure 7. Other accessories such as the PIM, LCM, or load shed kit must be connected after the APM. Measure the cable length from the furthest generator set to the last RBUS device in the system and compare to Figure 15. The maximum cable length depends on the number of optional modules connected.
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5 3 1 4 RXT APM PIB COM PWR B A GND 2 DIODE BOARD PIM COM PWR B A 6 COM PWR LCM or load shed kit B A Note: 1. 2. 3. 4. 5. 6. See Figure 15 for maximum total cable length. 6 Factory connection, diode board to APM PIB. Customer connections, generator 1 and generator 2 RDC2 controllers to APM diode board Connect one end of each cable shield to GROUND. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable Connect shields together.
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2.3 AC Voltage Output Connections 6. Connect generator set AC output leads to the APM contactors or to the circuit breakers installed in Section 1.3, if used. Be sure to connect generator 1 to contactor 1 and generator 2 to contactor 2 in the APM. See Figure 17 or the wiring diagram, Figure 33. 2.4 Ethernet Connection for OnCue Plus 8. If OnCuer Plus will be used, connect both RDC2 controllers to the Internet by connecting to the Ethernet modem or router on the site.
PAGE 14
3.2 Load firmware onto each generator set controller. Note: A personal computer (laptop) with Kohler SiteTecht software is required to complete the system installation and setup. SiteTecht software is available to Kohler-authorized distributors and dealers. Use a personal computer (laptop) and Kohler SiteTecht software to load RDC2 paralleling firmware version 105.4 or higher. Download the paralleling firmware from TechTools and save it on the laptop.
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4 Setup and Commissioning 4.3 The next procedures are required for setup and commissioning of the paralleling system. If the system does not include a programmable interface module (PIM), proceed to Section 4.4. Note: A personal computer (laptop) with Kohler SiteTecht software version 3.5 or higher is required to complete the system setup. SiteTecht software is available to Kohler-authorized distributors and dealers. 1.
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4.4 Perform the auto-discovery procedure. Note: This procedure is REQUIRED. 1. Close the circuit breakers on both generator sets and in the APM (if equipped with the optional circuit breaker kit). 2. Press OFF on generator set 2. Press RUN to start generator set 1. 3. After generator 1 starts, the controller cycles through the relays in the APM. This process is necessary for the APM to recognize the output that drives the contactor, which connects the generator set to the paralleling bus.
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4.5 Verify synchronization and calibration. 1. Start generator 1 by pressing RUN on the RDC2 controller. 3. Verify that the generators start, synchronize and close both contactors. This will enable the controllers to verify the metering. The engines may appear slightly unstable during the verification process. 2. When the generator reaches rated voltage and frequency, verify that the corresponding contactor in the APM closes. 4. Once the verification process is complete, the ATS will transfer.
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5.1 Synchronization and Paralleling The RDC2 controllers on Generator 1 and Generator 2 control the synchronizing and paralleling of the generators. Each controller is responsible for making the required adjustments to synchronize to the other generator and to share real and reactive load once the generators are both online. The synchronizing and paralleling process starts after the generator reaches rated voltage and frequency and consists of 3 steps: 1.
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If any voltage dip is observed (typically by dimming lights) when a generator closes the paralleling contactor after synchronizing, it may be necessary to determine if the fuel systems of the generators are allowing them to maintain a stable speed. (The speed must be changing at the moment that the contactor closes). If the throttle of one of the generators is closed or the generator fuel supply is exhausted, the generator will start to absorb power.
PAGE 20
Generator Management will start the second generator and run it for at least 5 minutes if it senses any of the following: D The running generator fails (disconnects from the paralleling bus). D A load is shed. Generator Management stops generators based on the Automatic Stop Minimum Percent Load (Automatic Stop) parameter and the load on the system. The Automatic Stop setting is adjustable using SiteTech.
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5.3.2 Order of Operation Auto-Off Functionality There are two methods for selection of the generator set order of operation: runtime hours selection mode and manual selection mode. Pressing the Auto and Off buttons simultaneously will cause the generator to attempt to unload and disconnect from the bus. The generators go into manual selection mode.
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5.4 Generator Set Maintenance 5.5 Faults When it is necessary to perform maintenance or service on the generator sets, use the following procedure to remove one generator set from the system at a time. Fault messages displayed on the RDC2 controller are shown in Figure 22 and Figure 23. To clear the warnings listed in Figure 22 press AUTO or OFF. 1. On the generator set to be serviced, press the AUTO and OFF buttons on the RDC2 controller simultaneously for about 1 second.
PAGE 23
Fault Text Description Possible Causes CfgModelNum The two generators which are intended to be paralleled have different model numbers. Incorrect configuration of one of the generators. Different generator types. The paralleled generator sets must be the same kW model. (i.e. two 14RESAs, two 20RESAs, or one 20RESA and one 20RESB.) LossOfComm2 The Primary controller has lost communication with the secondary controller. (A secondary controller was detected, then communication was lost.
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Fault Text Description Possible Causes LossOfField This generator has absorbed more than 25% reactive power (magnetic excitation current) for 20 seconds Generator voltage on this generator is not calibrated correctly. Generator voltage on other generator is not calibrated correctly. Bus voltage on this generator is not calibrated correctly. Bus voltage on the other generator is not calibrated correctly.
PAGE 25
5.6 Status Indicators The APM is equipped with an LED panel that indicates the system status. See Figure 24 and Figure 25. 1 Note: A model RXT transfer switch is required for power connection status indication. See Figure 25. 9 2 3 8 7 4 6 5 TT1596 1. 2. 3. 4. 5. 6. 7. 8. 9.
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6 OnCue Plus Generator Management System The APM kit includes two OnCuer activation codes to allow the connection of both generator sets to the OnCue Plus server. Follow the instructions in the OnCue Plus Operation manual to connect both generator sets to OnCue. The OnCue Plus Status view will show two generator sets. See Figure 27. The secondary generator set can monitor the RBUS devices such as the optional PIM, but cannot control them.
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7 Additional Troubleshooting If the paralleling system does not operate as expected, check the items in the following tables. Section 4 also includes some troubleshooting tips for problems that may arise during the initial setup. Breaker will not close in RUN. Check whether the other generator set is connected to the paralleling bus. YES Other breaker is closed. Stop the other generator set. NO Check whether the generator sees bus voltage (L2-L3 in SiteTech) above 25% of rated voltage.
PAGE 28
Auto-discovery does not complete. Check whether the Automatic Paralleling Module indicates that the generator is closed to the bus. The wait for auto-discovery can be as long as 30 seconds. After 30 seconds expires, try to close the contactor manually (jump L1 to the C wire on the coil). Check if it closes. YES NO YES NO Is the generator circuit breaker tripped? Device may already have auto-discovered to a different contactor.
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8 Diagrams and Drawings The paralleling system dimension drawing, wiring diagram, and schematic diagram are shown on the following pages. Also refer to Figure 7, Block Diagram, on page 5.
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Figure 31 Dimension Drawing ADV-8518 Sheet 1 30 TT-1596 3/15
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GM85145 Figure 32 Dimension Drawing ADV-8518 Sheet 2 TT-1596 3/15 31
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Figure 33 Wiring Diagram, GM85757 Sheet 1 32 TT-1596 3/15
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GM85757--A Figure 34 Wiring Diagram, GM85757 Sheet 2 TT-1596 3/15 33
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Figure 35 Schematic Diagram, GM85758, Sheet 1 34 TT-1596 3/15
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Figure 36 Schematic Diagram, GM85758, Sheet 2 TT-1596 3/15 35
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Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 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 9 Parts Lists Automatic Paralleling Module (APM) Circuit Breaker Kit, 14RESA Kit: GM85144-KP1-QS Qty.