KOHLER TT-1795 Emergency Stop Kit Installation Guide

KOHLER TT-1795 Emergency Stop Kit

Product Information

Specifications

• Model Numbers: 8/10/12RESV, 14/20RESA(L), 14/20RCA(L), 20RESC(L), 24/30RCL, 38RCLB, 48RCLB, 60RCLA, 26RCA(L)
• Market: Residential/Light Commercial
• Kit Numbers: GM113935-KP1-QS and GM113935-KP2-QS
• Firmware Requirement: RDC2 firmware version 5.5 or higher

Product Usage Instructions

Installation Instructions
Follow these steps to install the emergency stop kit:

1. Ensure you have the necessary kit components: E-stop, contact block (P/N GM108093), two leads, and push button (P/N GM108092).
2. Update the RDC2 firmware to version 5.5 or higher using a personal computer and Kohler SiteTech software or USB Utility if required.
3. For models without a knockout for the emergency stop switch, consider using the remote lockable emergency stop switch GM103279-KP1-QS.
4. Disconnect battery cables before starting work on the generator set to prevent accidental starting.
5. Follow the installation procedure in the specified order as outlined in the manual.

Safety Precautions
Observe the following safety precautions during installation:

• Disconnect battery cables before working on the generator set to avoid accidental starting.
• Remove the negative lead first and reconnect it last when working with the battery.

Installation Procedure

1. If necessary, update RDC2 firmware to version 5.5 or higher using a personal computer and Kohler SiteTech or USB Utility.
2. For RCA, RESV, and RESA/RESC Models:
3. Use the enclosure locking tool to open the enclosure roof.
4. Press the OFF button on the generator set controller.
5. Disconnect utility power supplying the battery charger by opening the circuit breaker.
6. Disconnect the generator set engine starting battery(-) lead first.
7. Remove the screws holding the controller in place.

Frequently Asked Questions (FAQ)

Q: What models are compatible with emergency stop kits GM113935-KP1-QS and GM113935-KP2-QS?
A: Models compatible with these kits include 8/10/12RESV, 14/20RESA(L), 14/20RCA(L), 20RESC(L), 24/30RCL, 38RCLB, 48RCLB, 60RCLA, and 26RCA(L).

• Original Issue Date: 5/20
• Model: 8/10/12RESV, 14/20RESA(L), 14/20RCA(L), 20RESC(L), 24/30RCL, 38RCLB, 48RCLB, 60RCLA, and 26RCA(L)
• Market: Residential/Light Commercial
• Subject: Emergency Stop Kit, GM113935-KP1-QS and GM113935-KP2-QS

Introduction

Kits GM113935-KP1-QS and GM113935-KP2-QS provide an emergency stop (E-stop) button for the residential generator sets. See Figure 1 for kit selection.

GM113935-KP1-QS

14RESA and 14RESAL
20RESA and 20RESAL
14RCA and 14RCAL
20RCA and 20RCAL
26RCA and 26RCAL
20RESC and 20RESCL
24/30RCL|

GM113935-KP2-QS

38/48RCLB
60RCLA

Figure 1 Kit Selection

• The e-stop assembly harness contains the E-stop, contact block (P/N GM108093) and two leads connected to the contact block. The push button (P/N GM108092) shipped loose from the harness.
• Install the emergency stop button as described in the following instructions.
• RDC2 firmware version 5.5 or higher is required for E-stop operation. Use a personal computer (laptop) and Kohler SiteTech software or the USB Utility to update the controller firmware, if necessary. See TP-6701, SiteTech Operation Manual, or TT-1636, Firmware Update Using the USB Utility, for instructions if necessary.
• Note: For existing RCL models that do not have a knockout in the enclosure panel for the emergency stop switch, the remote lockable emergency stop switch GM103279-KP1-QS is recommended.
• Read the entire installation procedure and compare the kit parts with the parts list at the end of this publication before beginning the installation. Perform the steps in the order shown.
• See Figure 2 for an illustration of the kit and Figure 3 for the kit location.

Safety Precautions

Observe the following safety precautions while installing the kit.

WARNING
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.

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.

Installation Procedure

Refer to the assembly drawing in Figure 3 as needed during the following procedure.

1. If necessary, use a personal computer (laptop) and Kohler SiteTech or the USB Utility to update the RDC2 firmware to version 5.5 or higher. See TP-6701, SiteTech Operation Manual, or TT-1636, Firmware Update Using the USB Utility, for instructions.

For RCA, RESV, and RESA/RESC Models:

1. Using the enclosure locking tool provided with the generator set, open the enclosure roof.
2. Press the OFF button on the generator set controller.
3. Disconnect the utility power that supplies the battery charger by opening the circuit breaker in the main distribution panel.
4. Disconnect the generator set engine starting battery(ies), negative (- ) lead first.
5. Remove the two screws holding the controller in place.
6. Being careful of the connections on the back of the controller, remove the controller to get access to the E-stop location inside the enclosure. Do not disconnect the controller.

For 14/20RESA(L)/RESC(L) models only:
Remove the plug from the opening located on the non-service side of the generator set enclosure. See Figure 4. Discard the plug.

1. For 14/20/26RCA(L) and 8/10/12RESV models only: Drill 1-inch diameter of the hole in the location shown in Figure 5. Remove the burr from the hole fully to engage the locking nut smoothly.

For RCL Models:

1. Using the enclosure locking tool provided with the generator set, open and remove the enclosure door on the service side of the generator set.

2. Press the OFF button on the generator set controller.

3. Disconnect the utility power that supplies the battery charger by opening the circuit breaker in the main distribution panel.

4. Disconnect the generator set engine starting battery(ies), negative (- ) lead first.

5. Drill a 1-inch (25.4 mm) hole in the enclosure panel. See Figure 6 for the hole location. Remove the burr from the hole fully to engage the locking nut smoothly.
   Note: Clean up any metal chips and debris after drilling.

6. Being careful of the connections on the back of the controller, remove the upper panel and support it to avoid strain on the wiring. Do not disconnect the controller.

7. Remove the knockout from the back of the controller box for the connection harness.

8. Install the grommet, X- 284- 7, in the new opening in the back of the controller box. See Figure 6.

9. Remove the notched access panel inside the enclosure. See Figure 6 for the removable panel location.

10. Carefully route the harness through the knockout hole in the back of the controller box and up to the hole in the enclosure.

11. Reinstall the notched access panel inside the enclosure. Make sure that the harness is routed through the notch in the corner.

For All Models:

1. For ease of assembly, make sure that the E-stop push button is pulled out to the non-activated position.

2. If the pushbutton and mounting flange arrive assembled, carefully remove the mounting flange from the push button using a flat screwdriver. Insert the E-stop pushbutton through the opening from the outside of the genset enclosure. Secure the pushbutton and shroud to the genset enclosure using a locking nut. See Figure 8.

3. Line up the mounting flange assembly on the inside of the genset and press the contact block onto the button to snap the E-stop pushbutton and mounting flange together.
   Note: Ensure the “Emergency Stop” text moulded into the shroud is in the correct orientation as shown in Figure 2.

4. Connect harness leads ESS and ESN to the E-stop switch contact block as shown in Figure 9.

For RCA, RESV, and RESA/RESC Models:

1. Turn the controller over and locate E-stop leads ESS and ESN, which are connected in the harness. See Figure 10. Disconnect leads ESS and ESN.
2. Connect lead ESS from the new E-stop harness to lead ESS in the genset wiring harness. Connect lead ESN from the new E-stop harness to lead ESN in the genset wiring harness. See Figure 11.
3. Replace the controller and secure it with two screws.

For RCL Models:

1. Remove the access panel (below the controller) to access terminal strip TB1, terminal 1, and 1A for connection to E- E-stop harness. See Figure 7.
2. Remove the jumper across terminals 1 and 1A. See Figure 7 and Figure 12.
3. Connect lead ESS from the new E-stop harness to terminal TB1- 1. Connect lead ESN from the new E-stop harness to terminal TB1- 1A. See Figure 12.
4. Check for and clean up any debris in the controller box and circuit breaker area. Carefully reinstall the controller panel and the access panel on the junction box.

For All Models:

1. Check that the generator set controller is OFF.
2. Reconnect the generator set engine starting battery, negative (- ) lead last.
3. Reconnect the utility power that supplies the battery charger by closing the circuit breaker in the main distribution panel.
4. Press the AUTO button on the generator set controller for automatic operation.

Close and lock the door/roof.

Emergency Stop Switch Operation

1. Push the red emergency stop button to stop the generator set. The generator set shuts down immediately and the controller displays Emerg Stop Shutdown. The generator set cannot be restarted until the emergency stop switch is reset.
2. To reset the generator set after an emergency stop:
3. Pull out the emergency stop button.
4. Open the enclosure roof to access the generator set controller. Press the OFF button on the controller to clear the shutdown condition.
5. Press the AUTO button for automatic generator set operation, if desired.

Lockout/Tagout:

1. The emergency stop button can be locked in the STOP position. Insert a lock through two openings in the yellow shroud to prevent the stop button from being pulled out. Remove the lock for normal operation. See Figure 13.
2. A lock is not required to keep the switch activated. The switch button will stay depressed until it is pulled out by the operator.

Parts List

Emergency Stop Kit

Kit: GM113935-KP1-QS

Qty.| Description| Part Number
1| Harness Assembly, E-Stop| GM113934
1| Installation Instructions| TT-1795
Kit: GM113935-KP2-QS

Qty.| Description| Part Number
1| Harness Assembly, E-Stop| GM115032
1| Grommet| X-284-7
1| Installation Instructions| TT-1795

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.

Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and any obligation or liability whatsoever. Contact your local Kohler generator set distributor for availability.

2020 Kohler Co. All rights reserved.

References

• Kohler Energy | Cleaner Energy Solutions for individuals, businesses and communities

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