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Kohler APM603 Generator Set

The Kohler APM603 is a generator set.

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Specifications

ControllerAPM603

Procedures

12
Complete the RSA III final installation installation
  1. Mount the RSA III box to the wall or to the electrical box in the wall if not already done; check that the box is square.
  2. Position the RSA III front panel assembly to the box and install four self-tapping screws X-67-154; do not tighten.
  3. Center the remote annunciator in the box and square with the wall; tighten the screws.
  4. Flush mount: place wall-mounting plate GM85126 behind the RSA III front panel assembly flange.
Configure the APM402 controllers for the remote serial annunciator installation
  1. Verify the controller defaults to a 19200 baud rate and Modbus address #1.
  2. If Modbus settings need altering, use SiteTech software to make the configuration changes.
  3. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM603 controllers for the remote serial annunciator installation
  1. Verify the controller is factory configured with RSA Baud Rate 19200, RSA Comm Protocol Modbus, and RSA Modbus Address 1.
  2. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the APM802 controllers for the remote serial annunciator installation
  1. Verify the controller is factory configured with speed 19200 baud, stop bit 1, parity without, function Modbus slave, slave number 1.
  2. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the DEC 3+ controller for the remote serial annunciator installation

⚠ After setting DIP switches, power down and then power up the controller for the change to be acknowledged.

  1. Set the controller Modbus address to #1 by placing DIP switches 6, 7, and 8 to the open position.
  2. The DEC 3+ controller baud rate is fixed at 19200; no change is required.
  3. If a communication module board was installed, download firmware version 1.23 or higher (red board) or 2.03 or higher (blue board).
  4. Replace the controller cover and hardware.
Configure the DEC 550 and DEC 6000 Controllers for the Remote Serial Annunciator installation
  1. Replace the controller cover and hardware.
  2. Press the Reset Menu key on the controller keypad.
  3. Go to Menu 14, Programming Mode, and press the down arrow key to Programming Mode.
  4. Enter the access code (factory default is 0) and press Enter.
  5. Go to Menu 13, Communications, and press the right arrow key to Protocol - Modbus.
  6. Set the controller Modbus address to #1 and press Enter.
  7. Set the Baud Rate to 19200 if not already shown.
Configure the DEC 8000 controllers for the remote serial annunciator installation
  1. Use the controller menus to change the setpoints: Contr. address 1, RS232(2) mode 0 - DIRECT, RS232(2) MBCSpd 1 - 19200, RS485(2) conv. ENABLED.
  2. For RS-485 port 2, enable the internal converter and set the Modbus communication speed to 19200 bps.
  3. Verify the RS-485 address on the controller matches the address on the RSA III master.
Configure the Decision-Maker 3000 and 3500 controllers for the remote serial annunciator installation
  1. Verify the controller defaults to a 19200 baud rate and Modbus address #1.
  2. If Modbus settings need altering, use SiteTech software to make the configuration changes.
  3. Verify the RS-485 address on the controller matches the address on the RSA III master.
Mount the Communication Module Board in the DEC 3+ Controller installation
  1. Remove the existing three nuts attaching the indicator panel circuit board; leave the existing washers in place.
  2. Attach the three spacers to the indicator panel circuit board studs.
  3. Position communication module board GM49791-1 on the spacers.
  4. Install three lock washers X-22-7.
  5. Install the existing three nuts on the spacers to secure the board; do not overtighten the nuts.
Select a Mounting Location for the RSA III installation

⚠ Locate all RSA III within 853 m (2800 ft.) of the controller.

Tools: Drill, Screwdriver

  1. Select a visible location for mounting the RSA III up to 853 m (2800 ft.) from the controller.
  2. Remove four screws X-67-154 from the RSA III bezel GM85134 and remove bezel from the RSA III box GM85123.
  3. Surface mount: drill pilot holes, create wiring opening, mount box to a standard 10 cm (4 in.) square electrical box.
  4. Flush mount with box GM85125: create wall opening and attach box to wall with user-supplied hardware.
  5. Flush mount with user-supplied Hoffman box A-SG8X8X4: drill four 4.4 mm (0.17 in.) holes using plate GM85126 as template.
Wire the RSA III installation

⚠ Hazardous voltage. Disconnect all power sources before opening the enclosure.

⚠ This equipment must be installed and serviced by qualified electrical personnel.

  1. Disconnect the 12/24-volt DC power source to each RSA III.
  2. Connect RS-485 wiring from the controller to the RSA III master P27 using Belden #9841 or equivalent.
  3. Connect RS-485 wiring from the RSA III master to the slave(s) in a daisy chain configuration.
  4. Set the termination resistor in P34 based on the number of Modbus devices on the network.
  5. Connect 12/24 VDC power to P37; the battery positive lead should be fuse protected.
  6. Set the P39 isolation jumper (isolated or non-isolated) per the controller used.
  7. Make local (hardwired) EPS and user-defined digital input connections on P41 and P42 as needed.
Wire the communication module board in the DEC 3+ controller installation
  1. Attach the 24-position ribbon cable GM32632 inline connector to communication module board P9.
  2. Attach the 10-position ribbon cable GM21340 to communication module board P8 and main circuit board P7.
  3. If GM49791-2 gauge drive circuit board was previously installed, reconnect cable P10 to the communication module board.
  4. For high battery voltage, connect communication board HBV harness GM35318 to T27 lead and terminal TB5-12.
  5. Connect user-supplied battery charger high battery voltage contacts to the remaining GM35318 terminal and TB5-6.
  6. For EPS Supplying Load, connect ATS emergency position auxiliary contacts to terminals TB5-3 and TB5-9.
  7. Make additional user-selected connections for user-defined digital inputs 1 and 2 to TB5.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

VoltagePhaseConnectionLeadsNotes
APM402 and Decision-Maker 3000 P21P21-1 GND Shield; P21-2 (+) White; P21-3 (-) BlackConnect shield at either end but not at both ends.
APM603 customer connection terminal block(+) White; (-) Black; Shield — do not connect at the customer connection terminal block; tape to insulate unused endConnect shield at the RSA III P27 connection but not at the APM603 customer connection terminal block.
APM802 TB10TB10-7 (-) Blue; TB10-8 (+) Green; Shield — do not connect at TB10 or base module; tape to insulate unused end120 ohm resistor located on the base module; connect shield at the RSA III P27 connection only.
Communication module board TB5 (DEC 3+)TB5-3 ATS Position Input Return; TB5-4 User 1 Input Return; TB5-5 User 2 Input Return; TB5-6 User 3 Input Return; TB5-9 ATS Position Input; TB5-10 User 1 Input; TB5-11 User 2 Input; TB5-12 User 3 InputTerminals 1, 2, 7, and 8 not used. User 3 Input reserved for high battery volts (HBV) on DEC 3+ controllers.
Decision-Maker 3+ P21P21-1 - Black; P21-2 + White; P21-3 GND ShieldConnect shield at either end but not at both ends.
Decision-Maker 3500 TB12COM (+) (+) White; COM (-) (-) Black; Shield — do not connect at TB12 or DEC 3500, tape to insulate unused endConnect shield at the RSA III P27 connection only.
Decision-Maker 550 and 6000 P20P20-1 GND Shield; P20-2 + White; P20-3 - BlackConnect shield at either end but not at both ends.
Decision-Maker 8000 RS-485A terminal: blue wire, High (H) or Positive (+); B terminal: green wire, Low (L) or Negative (-)120 ohm resistor located on the controller base box; connect shield at the RSA III P27 connection only.
P27 connector on RSA III slaveP27-1 (-) Black (from master or previous slave); P27-2 (+) White (from master or previous slave); P27-3 Shield (from master or previous slave); P27-4 (-) Black (to next slave or terminating resistor); P27-5 (+) White (to next slave or terminating resistor); P27-6 Shield (to next slave or open)RS-485 daisy chain from master to slave.
P27 connector on master RSA IIIP27-1 (-) Black (from controller); P27-2 (+) White (from controller); P27-3 Shield (from controller); P27-4 (-) Black (to slave or terminating resistor); P27-5 (+) White (to slave or terminating resistor); P27-6 Shield (to slave or open)RS-485 communication from controller to RSA III master. Connect shield at either end but not both ends.
P27-1 (Controller to RSA III master)(-) Black (from controller)RS-485 communication; use Belden #9841 or equivalent.
P27-2 (Controller to RSA III master)(+) White (from controller)RS-485 communication.
P27-3 (Controller to RSA III master)Shield (from controller)Connect the shield wire at either end but not at both ends.
P27-4 (Master to slave)(-) Black (to slave or terminating resistor)RS-485 communication.
P27-5 (Master to slave)(+) White (to slave or terminating resistor)RS-485 communication.
P27-6 (Master to slave)Shield (to slave or open)RS-485 communication.
P37 power connectionsP37-1 Ground; P37-2 12/24 VDC battery input1 (not polarity sensitive); P37-3 12/24 VDC battery input2 (not polarity sensitive)Requires 12/24-volt, 200 mA (min.) DC power source; voltage should match generator set starting system.
P37-1GroundPower/CAN connections.
P37-212/24 VDC battery input1 (not polarity sensitive)Attach battery positive (+) at the starter solenoid.
P37-312/24 VDC battery input2 (not polarity sensitive)Attach battery negative (-) at the engine ground.
P40 output connectionsP40-1 Common fault relay normally closed; P40-2 Common fault relay common; P40-3 Common fault relay normally open; P40-4 Horn relay normally closed; P40-5 Horn relay common; P40-6 Horn relay normally openDry contacts rated at 220 VAC @ 0.8 amps and 30 VDC @ 2 amps.
P41 input connectionsP41-1 Local ATS emergency on input (EPS); P41-2 Local ATS emergency on input return (EPS); P41-3 User-Defined Digital input 1; P41-4 User-Defined Digital input 1 return; P41-5 User-Defined Digital Input 2; P41-6 User-Defined Digital Input 2 return; P41-7 User-Defined Digital Input 3; P41-8 User-Defined Digital Input 3 returnEPS and user-defined digital inputs typically supplied via remote Modbus RS-485 but may be hardwired locally.
P42 connectionsP42-1 User-defined digital input 4; P42-2 User-defined digital input 4 return; P42-3 User-defined digital input 5; P42-4 User-defined digital input 5 returnLocal user-defined digital inputs 4 and 5.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Parts

2
Part #DescriptionQtySystem
APM603APM603 controller uses a CR1220 internal battery to preserve the time, date, and generator set events.1Controller Amazon eBay $1500.00
CR1220Real Time Clock (RTC) battery has an expected lifespan of ten years when the controller is powered by an engine battery or two years when the controller is not powered by an engine battery.Battery Amazon eBay

Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Available documents

Reference — FortHaysCaseStudy (Kohler)Parts manual — Kohler-Controller Brochure (Kohler)Service manual — Annunciators tt1625 (Kohler)Service manual — apm603 sb797 (Kohler)Service manual — tp7151 (Kohler)Service manual — tt1625 (Kohler)

This page was generated from the 6 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.