Kohler Tt1584PIM
description
Transcript of Kohler Tt1584PIM
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INSTALLATION INSTRUCTIONS
TT-1584 2/12a
Original Issue Date: 2/12
Model: 14RESA/RESAL, 20RESA/RESAL, and 48RCL
Market: Residential/Light Commercial
Subject: Programmable Interface Module (PIM) Kits GM81529-KP1-QS
Introduction
The optional Programmable Interface Module (PIM)
provides two programmable inputs and six
programmable outputs for connection to
customer-supplied equipment. The PIM operates only
with generator sets equipped with the Kohler RDC2 or
DC2 controller, including the following models:
14RESA/RESAL
20RESA/RESAL
48RCL
ThePIM ismounted in aNEMA3Renclosure, which can
be installed indoors or outdoors. The PIM with
enclosure is shown in Figure 1. For outdoor installation,
use watertight conduit hubs.
ADV--8199
Figure 1 Programmable Interface Module (cover
removed for illustration)
Inputs and outputs are factory-set to theevents shown in
Figure 7. The inputs and outputs 3--6 can be changed
using a laptop computer connected to the RDC2 or DC2
controller and Kohler SiteTech software . SiteTech is
available to Kohler-authorized distributors.
A maximum of three accessory modules can be
connected to the generator set. Accessorymodules can
include one programmable interface module (PIM), one
Model RXT transfer switch, and/or one load control
module (LCM).
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.
OnCue Remote Monitoring and
Control
The Kohler OnCue Generator Management System
can be used to monitor the PIM inputs and outputs.
OnCue can also be used to remotely control PIMoutputs
3 through 6. For example, connect output 3 to the storm
shutters on your vacation home and label it Storm
Shutters in the Power Chain view in OnCue. When bad
weather is forecast, you can use your computer to close
the storm shutters from a remote location.
The OnCue kit is available from Kohler-authorized
distributors and dealers. See TP-6796, OnCue
Software Operation Manual, for instructions to connect
the generator set to the Internet and use OnCue on a
personal computer.
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Safety Precautions
Observe the following safety precautionswhile installing
the kit.
Accidental starting.Can cause severe injury or death.
Disconnect the battery cables beforeworking on the generator set.
Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.
Hazardous voltage.Will cause severe injury or death.
Disconnect all power sources beforeopening the enclosure.
DANGER
Installation Procedure
1. Press the OFF button on the generator sets
RDC2/DC2 controller.
2. Disconnect the utility power to the generator set.
3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
4. Remove the PIM enclosure cover. Cover the PIM
circuit board to protect it from metal chips and
debris.
5. Cut holes in the PIMenclosure for the generator set
communication leads and input and output leads.
For outdoor installation, use weather-tight conduit
connectors.
Note: Use separate conduit for the low-voltage
communication leads to the generator set
controller. To ensure separation of circuits
per NEC requirements, route low-voltage
AC and DC wiring separately from
line-voltage wiring.
6. Mount the PIM enclosure to a wall. See the
dimension drawing in Figure 26 for the mounting
hole size and locations.
Note: The mounting holes have gaskets to seal
out moisture. Use washers with the
mounting screws to protect the gaskets.
7. Connect A, B, PWR, andCOMon connector P10 to
the corresponding generator set connectors. See
Figure 2 through Figure 5. Use Belden #9402
(4-conductor) or equivalent 20 AWG shielded,
twisted-pair cable. The maximum cable length is
61 m (200 ft.).
Note: If a longer cable run is required, or if
additional accessories such as a transfer
switch or a load control module (LCM) are
used, seeCommunication Connectionswith
Additional Accessories on page 5.
1
ADV-7876
1. Customer connection terminal block
Figure 2 14/20RESA Terminal Block Location
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1. Customer connection terminal block
Note: Access panel removed for illustration.
Figure 3 Model 48RCL Terminal Block Location
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1. TB4, relay 3 and relay 4 connections
2. P10, connection to generator set3. TB2, input 1 and input 2 connections
4. LED1, online
5. TB3, relay 1 and relay 2 connections6. TB5, relay 5 and relay 6 connections
7. LED2, power
6
ADV--8199
1
3
2
4
7
Figure 4 PIM Circuit Board Connections and LEDs
Generator Set
Connect one end of each cable shieldto GROUND at the generator set.
Leave one end of each cable shielddisconnected at the last device.
PIM1
COM
PWR
B
A
1. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable
GND
A
B
COM
PWR
3
4
TB1
NOTE: See Figure 2 or Figure 3 for the terminal block
location on the generator set. Check the decal on thegenerator set for terminal block connections.
RBUS
12 VDC
Figure 5 PIM Communication Connections to Generator Set
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8. Connect customer equipment to inputs 1 and 2 on
TB2 on the PIM circuit board. See Figure 6 for the
cable size. See the wiring diagram in Figure 27.
9. Connect customer equipment to output relays 1
through 6 on TB3, TB4, and TB5. Note the
factory-default output settings shown in Figure 7.
Refer to the wiring diagram in Figure 27 and
connect to each relays normally open or normally
closed contacts as required.
10. Turn the locking tab out so that the enclosure door
can be secured with a padlock.
11. Install the door and secure with the door screw.
Lock the enclosure door with a padlock to prevent
unauthorized entry.
12. Reconnect the generator set engine starting
battery, negative (--) lead last.
13. Reconnect utility power to the generator set.
14. Press the AUTO button on the generator set
controller.
PIM Connection Specifications
Input Rating 10 mA @ 12 VDC dry contact
Output Relay Rating 10 A @ 120 VAC
Wire Size 12--24 AWG
Screw Torque 7 in. lbs
Figure 6 Input/Output Connection Specifications
15. Note the factory-assigned functions for the digital
outputs shown in Figure 7. Use a personal
computer connected to theRDC2or DC2 controller
and Kohler SiteTech software to change the
input and output functions, if necessary. Available
input and output functions are listed in Figure 16
and Figure 17. See TP-6701, SiteTech Software
Operation Manual, for instructions.
PIM Connection SiteTech Name
DefaultSetting(Event)
Input 1 TB2 IN1 Digital Input B1 None
Input 2 TB2 IN2 Digital Input B2 None
Output 1 TB3
Relay 1
Digital Output B1 Generator
Running
Output 2 TB3
Relay 2
Digital Output B2 Common Fault
Output 3 TB4
Relay 3
Digital Output B3 Low Battery
Voltage
Output 4 TB4
Relay 4
Digital Output B4 Not in Auto
Output 5 TB5
Relay 5
Digital Output B5 Cooldown
Output 6 TB5
Relay 6
Digital Output B6 Normal Source
Failure
Figure 7 Inputs and Outputs
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Communication Connections with
Additional Accessories
See Figure 9 through Figure 14 for connection options
with up to three accessory modules. Accessory
modules can include one Model RXT transfer switch,
one programmable interface module (PIM), and/or one
load control module (LCM).
See Figure 8 for the maximum total cable length with 1,
2, or 3 accessory modules per cable run.
Use Belden #9402 (4-conductor) or equivalent
20 AWG shielded, twisted-pair cable. Note the shield
connections shown in Figure 9.
If longer cable runs are required, #12--14 AWG wire
can be used for the COMand PWR connections. The
maximum total cable length is the value shown for
#12 or #14 AWGwire in Figure 8. The 20 AWG cable
used for communication connections A and B (only)
can be as long as 152 m (500 ft.).
Cable (TB1--PWR and COM)
Maximum length per run, meters (ft.)
Number of Modules (ATS, PIM, and LCM) per Run
1 Module 2 Modules 3 Modules
Belden #9402 or equivalent 20AWG 61 (200) 31 (100) 21 (67)
14 AWG 152 (500) 152 (500) 122 (400)
12 AWG 152 (500) 152 (500) 152 (500)
Figure 8 Total Cable Lengths with Accessory Modules Connected
PIM
LCM
Generator Set
COM
PWR
COM
PWR
B
A
B
A
COM
PWR
B
A
Connect one end of each cable shieldto GROUND at the generator set.
Leave one end of each cable shield disconnected at the last device.
RXT1
COM
PWR
B
A
COM
PWR
B
A
Connect shields togetheras shown.
1. Communication cable Belden #9402 or equivalent
20 AWG shielded, twisted-pair cable
GND
A
B
COM
PWR
3
4
TB1
NOTES:
See thegeneratorset InstallationManual for terminal
block location on generator set. Check the decal on
the generator set for terminal block connections.
See Figure 8 for maximum total cable length per run
(1 run shown)
Current transformer must be installed on theemergency source leads.
RBUS
12 VDCCOM
PWR
A
B
Figure 9 Communication Connection Details with Model RXT Transfer Switch
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LCM
Generator Set
COM
PWR
B
A
Connect one end of each cable shieldto GROUND at the generator set.
Leave one end of each cable shield disconnected at the last device.
PIM1
COM
PWR
B
A
COM
PWR
B
A
Connect shields togetheras shown.
1. Communication cable Belden #9402 or equivalent 20 AWG
shielded, twisted-pair cable2. Engine start leads 3 and 4. See the ATS manual for cable
size specifications.
GND
A
B
COM
PWR
3
4
TB1
NOTES:
See thegeneratorset InstallationManual for terminal
block location on generator set. Check the decal on
the generator set for terminal block connections.
See Figure 8 for maximum total cable length per run
(1 run shown)
Current transformer must be installed on theemergency source leads.
RBUS
12 VDCCOM
PWR
A
B
ATSModels RDTor RSB
2
2 4
3
Figure 10 Connection Details with Model RDT or RSB Transfer Switch
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NOTES:
See the generator set Installation Manual for terminal block location on
generator set. Check the decal on the generator set for terminal block
connections.
See Figure 8 for maximum total cable length per run (3 runs with 1module
each shown).
See Figure 9 for communication connection detail (A and B, PWR andCOM).
Use splices or wire nuts to collect multiple leads for connection to the
generator set terminal block. See Figure 12.
1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803
PIM
LCM
RXT ATS
Generator Set
TB1
1
1
1
Figure 11 Accessory Module Connections, Star Configuration (three cable runs with one module each)
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1. Splice
Generator Set
Generator Set Terminal Block TB1.See the generator set Installation Manual for location.Check the decal on the generator set for terminal block connections.
COM
PWR
B
A
Connect all of the shield leads on thisend to GROUND at the generator set.
COM
PWR
B
A
To GROUND
9402 CABLE
9402 CABLE
A
B
COM
PWR
3
4
TB1
RBUS
12 VDC
GND
Figure 12 Multiple Connections to the Generator Set
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1. Belden #9402 or equivalent, 20 AWG shielded cable with 2 twisted pairs tp6803
PIM
LCM
RXT ATS1
1
1
Generator Set
TB1
NOTES:
See the generator set Installation Manual for terminal block
locationongenerator set. Check thedecalon thegenerator set for
terminal block connections.
See Figure 8 for maximum total cable length with12 or 14 AWG wire.
See Figure 9 for communication connection (A and B, PWR andCOM) detail. Connect the cable shield to ground at the generator
set.
Figure 13 Accessory Module Connections (two cable runs with one and two modules shown)
1. Belden #9402 or equivalent, 20 AWG shielded cable (use one pair); or
Belden #8762 or equivalent 20 AWG shielded cable2. 12--14 AWG wire
tp6803
PIM
LCM
RXT ATS
1
1
1
Generator Set A and BPWRCOM 2
2
22
2
2
A and B
A and B
A and B
PWRCOM
PWRCOM
PWRCOM
NOTES:
See the generator set Installation Manual for terminal block location on
generator set. Check the decal on the generator set for terminal block
connections.
SeeFigure 8 formaximum total cable length with 12 or 14 AWGwire. (1
run with 3 modules shown).
See Figure 9 for communication connection (A and B) detail. Connectthe cable shield to ground at the generator set.
Figure 14 Accessory Module Connections with 12--14 AWG Power Leads (one cable run with three modules
shown)
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PIM Inputs and Outputs
Connect customer-supplied equipment to the PIM input
and output connections. Connect to the normally open
or normally closed output contacts as required for the
application. See the wiring diagram for connection
details.
Run/Common Fault Outputs
The first two PIM outputs are factory-set to Generator
Running and Common Fault. See Figure 7. The
generator running output is activated when the
generator set is running. The common fault output is
activated on a fault.
Changing Input and Output Settings
Use a laptop computer connected to the RDC2 or DC2
controller and running Kohler SiteTech software to
change the event settings for factory-set inputs and
outputs. Be sure to select Digital Inputs B1--B2 and
Digital Outputs B1--B6 in SiteTech. See Figure 7 and
Figure 15. Digital Inputs A1--A2 and Digital Outputs
A1--A2 and B7--B12 do not apply to the PIM.
Note: SiteTech software is available to
Kohler-authorized distributors.
The available programmable input and digital output
functions are listed in Figure 16 and Figure 17. At
installation, note the input and output connections.
Then use Kohler SiteTech software to assign the
corresponding input and output functions if they are
different than the defaults shown in Figure 7.
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tt15841. PIM Digital Input B1 settings
2. PIM Digital Output B3 settings
2
Figure 15 SiteTech Screen, Input and Output
Settings
Input Level
Auxiliary Input Shutdown
Auxiliary Input Warning
Battery Charger Fault Warning
Chicago Code Active Notice
Engine Fuel Level Critically High Warning
Engine Fuel Level High Warning
Engine Fuel Level Low Warning
Engine Fuel Level Low Shutdown
Engine Oil Level Low Warning
Engine Oil Level Low Shutdown
Fuel Pressure Low Warning
Fuel Tank Leak Shutdown
Fuel Tank Leak Warning
Ground Fault Input Warning
Remote Reset Status
* Some inputs do not apply to all models.
Figure 16 Programmable Inputs
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Digital Output Level * 14/20 48
AC Sensing Lost W
AC Sensing Lost S
Alternator Protection S NA NA
Always Off N
Always On N
ATS Fail To Transfer W
ATS Fail To Transfer S NA NA
ATS Phase RotationMismatch (3-phase only)
W NA
Auxiliary Input W
Auxiliary Input S
Battery Charger Fault W
Battery Voltage High W
Battery Voltage Low W
Chicago Code Active N
Common Fault N
Common Warning W
Cranking Voltage Low W
ECM Communication Loss S NA
Emergency Power SystemSupplying Load
N
Emergency Stop S NA
Engine Coolant Level Low S NA
Engine CoolantTemperature High
W NA
Engine CoolantTemperature High
S NA
Engine CoolantTemperature Low
W NA
Engine CoolantTemperature No Signal
S NA
Engine Cooldown Active N
Engine Fuel LevelCritically High
W
Engine Fuel Level High W
Engine Fuel Level Low W
Engine Fuel Level Low S
Engine Oil Level Low W
Engine Oil Level Low S
Engine Oil Pressure Low W NA
Engine Oil Pressure Low S
Engine Oil Pressure NoSignal
S NA
Engine Speed High S
Engine Speed Low S
Engine Start Aid Active N
Engine Start Delay Active N
Digital Output Level * 14/20 48
Fuel Pressure Low W
Fuel Spill N
Fuel Tank Leak S
Fuel Tank Leak W
Generator Frequency High S
Generator Frequency Low S
Generator Running N
Generator True TotalPower High
S NA NA
Generator Voltage L1--L2High
S
Generator Voltage L1--L2Low
S
Generator Voltage L2--L3High (3-phase only)
S NA
Generator Voltage L2--L3Low (3-phase only)
S NA
Generator Voltage L3--L1High (3-phase only)
S NA
Generator Voltage L3--L1Low (3-phase only)
S NA
Ground Fault Input W
Load Priority1 Shed ** Status NA NA
Load Priority2 Shed ** Status NA NA
Load Priority3 Shed ** Status NA NA
Load Priority4 Shed ** Status NA NA
Load Priority5 Shed ** Status NA NA
Load Priority6 Shed ** Status NA NA
Locked Rotor S
Low Fuel N
Maximum AlternatorCurrent Low
S NA NA
Minor Fault N
NFPA 110 Alarm Active N
Not In Auto W
Over Crank S
Speed Sensor Fault S
System Ready N
* Level: N = Notice, S = Shutdown, W = Warning
Indicates output is remotely controlled through OnCue
Model RXT ATS required
From a digital input
Any of several conditions
** LCM required
NA: Not applicable for these models
Figure 17 Programmable Digital Outputs
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PIM Status Menu on the RDC2
Controller
The RDC2 controller displays PIM input and output
status in the menu shown in Figure 18. This is a status
display menu only. Input and output settings cannot be
changed from the RDC2 controllers user interface.
Refer to the generator set Operation Manual for
instructions to navigate the RDC2 menus, if necessary.
tp6810
PIMStatus:
PIM 1 ---->
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OnCue Remote Monitoring and
Control
The Kohler OnCue Generator Management System
can be used to monitor the PIM inputs and outputs with
your PC or laptop computer. OnCue can also be used to
remotely control PIM outputs 3 through 6 and to change
the output labels in OnCues Power Chain view.
Note: PIM outputs 1 and 2 are factory-set to Run and
Common Fault They are controlled by the
generator set and cannot be controlled remotely
through OnCue.
OnCue communicates with the PIM through the RDC2
or DC2 controller on the generator set. See the
generator set Installation Manual for instructions to
connect the generator set to the Internet.
The OnCue kit is available from Kohler authorized
distributors and dealers. See TP-6796, OnCue
Software Operation Manual, for instructions to use
OnCue on a personal computer.
Remote Control Example
1. Connect output 3 to the storm shutters on your
vacation home.
2. Use OnCue to connect to the generator set
controller and select the Power Chain view.
3. Select Edit Mode in the toolbar at the top of the
OnCue screen.
4. On the picture of the the PIM, click on the label for
output 3 and type in Storm Shutters.
5. Select Control Mode in the toolbar at the top of the
screen.
6. On the picture of the the PIM, click on Storm
Shutters to turn the output on or off. The status
indicator flashes for about 5 seconds and then
changes to show the new status: green for on or
gray for off.
When you click on an output in OnCues control mode,
the event setting changes from its original setting to On
or Off. The output can then only be controlled with
OnCue. It will no longer be controlled by the generator
set.
Kohler SiteTech software can be used to set the
outputs back to generator-controlled events, if
necessary. SiteTech is available to Kohler-authorized
distributors.
1
1. Edit mode and control mode selections
2. PIM outputs for remote control
2
Figure 19 OnCue Power Chain View
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TroubleshootingUse the flowcharts in Figure 20 through Figure 22 to
diagnose problems with the PIM operation.
Also see the next section, Verify that the Controller
Recognizes the PIM.
Check PIM outputstatus in controller
menu. SeeFigure 18.
Verify that only onePIM is connected.
Online LED may have adefect but does not affect
operation. Continuechecking functionality.
Check communication A & Bconnections at:1) PIM2) Genset connectionterminal block
Online LED Blinking
NO
YES
NO NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
NO
PIM notresponding
Power LEDSteady ON? *
Online LEDSteady ON? *
Verify correct versionof PC software is
installed
Device shown onSiteTech/OnCue?
Verify I/O parametersare set up for desired
functionality
Number of errors andtimeouts steady?See Figure 25.
PIM ID does notchange over time.
LED blinking fasterthan once/second?
Ensure the cable runs fromgenset to PIM are withinspecifications (cable size andlength)
If problems persist, contactthe Kohler GeneratorService Department.
Go to Figure 21.
Go to Figure 22.
* See Figure 4 for LED locations on the PIM circuit board.
Figure 20 PIM Troubleshooting Chart, Part 1 of 3
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Is voltage lowbut not zero?
Check the cable sizeand length to verifythey are within therange shown in
Figure 8.
Check for 10--16 VDCat the PWR and COMconnections on the
generator set.
Check the wire runfrom generator set to
PIM.
NONO
YES
YES
Check voltage to thecontroller. See controllertroubleshootinginformation and wiringdiagrams in the generatorset service manual.
Check connectionsfrom controller to
customer connectionson generator set.YES
Power LED may have adefect but does not affect
operation. Continuechecking functionality.
Voltage between10 and 16 VDC?
Check power connection at:1) PIM2) Genset connectionterminal block3) Starting battery
NO
Power LEDis not lit
Figure 21 PIM Troubleshooting, Part 2 of 3, Troubleshooting Power to the PIM
Functions correctlyonly if connected
individually.
NO
YESYES
PIM functions correctlyonly after cycling power.
If problems persist, contactthe Kohler GeneratorService Department.
Disconnect RBUSmodules and verify thatSiteTech/OnCue showsno devices connected.
Verify that the maximumnumber of allowed devices
is not exceeded.
Verify that each deviceserial number is different.
NO
YES
YES
YES
YES
Verify that the USB cableis not connected to
generator controller duringpower cycles.
Verify that all devices areseen by SiteTech afterindividual connection
sequence.
Figure 22 PIM Troubleshooting Chart, Part 3 of 3
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Verify that the Controller Recognizes the PIM
There are two ways to verify that the RDC2 controller
recognizes the PIM.
On the RDC2 controller, navigate to the Networking
Menu and check the number of modules connected
and the information for remote devices. See
Figure 23 and Figure 24.
For the RDC2 or DC2 controller, use a laptop
computer connected to the controllers USB port and
KohlerOnCue or SiteTech software to check that
the PIM appears in the Power Chain view. See
Figure 19. In the Parameters view, check that the
RBUS network screen shows the correct number of
RBUS devices connected (RXT transfer switch, PIM,
and LCM, if used). See Figure 25.
tp6804
Modules Connected:3
Module Timeouts:1234
Net Cycle Time:123ms
Module Errors:1234
< ---- Return
RDRemote ---->Devices
See Figure 24.
Networking---->
Information
Networking---->
Status
RBUS ---->Information
Configuration
Figure 23 RDC2 Controller Menu, Networking Information
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tp6810
Device Status:Connected
RD
Firmware Ver.:122
ModBus ID:12
S/N: XXXXXXXXX
Return ---->
S/N: XXXXXXXXX
Comm. Errors:12345
Comm. Timeouts:12345
...
Connected:MM/DD/YY 12:12
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Figure 25 RBUS Device Parameters in OnCue or SiteTech
Parts List
Programmable Interface Module (PIM)
Kit: GM81529-KP1-QS
Qty. Description Part Number
1 PIM, Assy NEMA 3R GM81529-1
1 Installation Instructions TT-1584
Diagrams and Drawings
The PIM dimension drawing, wiring diagram, and
schematic are shown on the following pages.
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Figure 26 Dimension Drawing ADV-8199
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Figure 27 Wiring Diagram, GM84085
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Figure 28 Schematic Diagram, GM84086