Industrial Generator Set Accessories

Generator Set Controller

The APM603 generator set controller provides advanced control, system monitoring, and system diagnostics for a single
generator set or paralleling multiple generator sets. The APM603 interfaces the generator set to other power system equipment
and network management systems using standard industry network communications. It uses a patented digital voltage regulator
and unique software logic to manage alternator thermal overload protection as well as serves as an overcurrent protective relay,
features normally requiring additional hardware. The APM603 controller meets NFPA 110, Level 1.

Display, Interface, and Accessibility On- board Diagnostics

D A 7-inch color TFT touchscreen for easy local access to D Immediate visibility of warnings and faults with text
data. description and code display.
d Home screen can be customized to show critical data d 15 seconds of critical data are captured around each
at a glance. warning and fault
d Create a custom favorites list for quick access to d Critical data can be viewed on the display and
important data downloaded
D Measurements are selectable in metric or English units. D Store up to 10,000 events locally along with historical
data logging of successful starts.
D Supports Modbusr protocol through serial bus and
Ethernet networks, and supports SNMP and BACnetr d Accurate time stamp from real-time clock
through Ethernet networks.
d Event log can be downloaded
Global Support D Data logging of customized parameter list for report
D Sales, installation, and service support from more than generation and advanced troubleshooting.
800 Kohler and SDMO service providers around the d Store to external USB drive for easy transfer to
world. another device

Modbusr is a registered trademark of Schneider Electric.

BACnetr is a registered trademark of ASHRAE.

G6-162 (APM603) 12/21h Page 1

 Fault Annunciator LEDs: Touchscreen
Red- Shutdown
Yellow- Warning
Alarm
APM603
USB Connections
with cover

Alarm Silence/Lamp Test

Button with LED
Emergency
Stop Button

Master Control Buttons with

LEDs: Off/Reset, Auto, and Run

Controller Features Communication

AC Output Voltage Regulator Maximum of r10% of the system USB Port (1) Mini-USB port for PC connection
Adjustment voltage (1) USB port for storage device
Alarm Horn Indicates a generator set warning Serial (RS-485) Port (1) Non-isolated for RSA III
or shutdown condition (1) Isolated for Modbus devices
Alarm Silence For NFPA-110 application or user (1) Isolated for paralleling communication
convenience Ethernet Port (1) RJ45 for Modbus TCP, SNMP, and
BACnet
Alternator Protection Generator set overload and short
circuit protection
Cyclic Cranking Provides automatic restart after a Controller Specifications
failed start attempt with
programmable on/off time and Nominal voltage 12 or 24 VDC
number of attempts protected against reverse battery
ECU Diagnostics Displays engine ECU fault codes connection
and descriptions for engine Power 800 mAmps at 12 VDC
troubleshooting 400 mAmps at 24 VDC
Emergency Stop Button Shuts down the generator set
Operating Temperature - 40_C to 70_C (- 40_F to 158_F)
immediately, for emergency
situations Storage Temperature - 40_C to 85_C (- 40_F to 185_F)
Engine Start Aid Control for an optional engine Humidity 5% to 95% non-condensing
starting aid Display Size, W x H 154 x 86 mm (6.0 x 3.4 inches)
Environmentally Sealed Three master control buttons with Protection Index IP65 Front
Membrane Keypad LEDs: Off/Reset, Auto, and Run
Patented High-Speed RMS r0.25% no-load to full-load
Digital Voltage Regulator regulation with three-phase true
RMS sensing
Lamp Test Verifies functionality of the
indicator LEDs
Real-time Clock Includes battery back-up to retain
date and time through controller
power cycle
Remote Reset Allows remote fault resets and
restarting of the generator set
Remote Monitoring Panel Compatible with the Kohlerr
Remote Serial Annunciator
Run Time Hourmeter Displays generator set run time
Run Relay Indicates that the generator set is
running
Time Delay Engine Cooldown Time delay before the generator
(TDEC) set shuts down
Time Delay Engine Start (TDES) Time delay before the generator
set starts

G6-162 (APM603) 12/21h Page 2

 Paralleling Features Troubleshooting Features
D Isochronous control with real and reactive load sharing with other D 15 seconds of key data automatically captured around each warning
APM603 controller equipped generator sets and shutdown
d Supports paralleling up to 8 generators d Data can be exported for detailed analysis
D Random first-on logic to prevent two or more generator sets from d Data can be viewed on controller for convenient on-site
closing to a dead bus and provides the fastest response for a single troubleshooting support
generator online D Configurable data logger will allow you to select parameters to
D Automatic synchronizer with dead bus closing monitor
D Soft loading and unloading for generator management d Data stored to USB device for flexibility on amount of data stored
and ability to export for detailed analysis
D Protective relay functions: d Data capture controlled by user to allow capturing specific data
d Synch check (25C) required
d Over current (51)
d Over frequency (81O)
d Over power (32O) NFPA 110 Requirements
d Over voltage (59) In order to meet NFPA 110, Level 1 requirements, the generator set
d Reverse power (32R)
controller monitors the engine/generator functions/faults shown below.
d Reverse reactive power (32RQ)
d Under frequency (81U) D Engine functions:
d Under voltage (27) d Overcrank
D Generator management to allow the start and stop of generators d Low coolant temperature warning
d High coolant temperature warning
based on load demand or state of other generators d High coolant temperature shutdown
d Fuel level d Low oil pressure shutdown
d Run time d Low oil pressure warning
d Manual order d High engine speed
d Time of day d Low fuel (level or pressure) *
d Efficiency d Low coolant level
D Simplified paralleling system view from any generator controller in d EPS supplying load
the system d High battery voltage
d Low battery voltage
D General functions:
Overcurrent Protective Device d Master switch not in auto
d Battery charger fault *
D Provides protection against line-to-line and line-to-neutral faults d Lamp test
D Uses thermal and instantaneous current limit settings for alternator d Contacts for local and remote common alarm
protection d Audible alarm silence button
D Includes a maintenance mode for arc flash reduction per NEC 240.87 d Remote emergency stop *
* Function requires optional input sensors or kits and is engine dependent,
Load Management Features see Engine Data.

D Programmable outputs included to command the connect and

disconnect of loads based on generator or paralleling system state
Standards
d Loads connected based on available capacity The generator set controller has been tested and verified for compliance
d Loads disconnected at system startup with the following standards.
d Loads disconnected based on a maximum kW setting or
underfrequency setting D NFPA 99
D Supports up to 16 prioritized load steps per system D NFPA 110, Level 1
d Can be used on a single generator system D CSA 282-09
d Can be combined in a paralleling system for a total system load D UL 6200
control capability D ASTM B117 (salt spray test)
D Simplified load management system view from any generator
controller in the system
D Requires input/output module option

Advanced Programmable I/O

D Configurable inputs and outputs can be programmed for customer
specific use
D PLC-like capability for applying logic to customize generator system
behavior

G6-162 (APM603) 12/21h Page 3

 Controller Functions
The controller displays warning, shutdown, and status messages. All functions are available as relay outputs.
Warning causes the yellow fault LED to show and sounds the alarm horn, signaling an impending problem.
Shutdown causes the red fault LED to show, sounds the alarm horn, and stops the generator set.

The controller communicates with the engine ECU and supports a large number of warning and shutdown events that are not listed here. This table
highlights the items required for NFPA 110.

Event Warning Shutdown Event Warning Shutdown

Alternator Thermal Protection [ D Remote Emergency Stop Shutdown [ D
Battery Charger Fault * Y Reverse Power Shutdown [ D
CAN Option Board1 Comm Loss Y Reverse VAR Shutdown [ D
Critically Low Fuel Level (diesel) * Y Under Frequency Shutdown [ D
ECU Diagnostic Event Y Under Frequency Warning Y
ECU Mismatch Shutdown [ D Under Voltage Shutdown (L- L, L- N, each
phase) [ D
Fuel Leak Alarm (diesel) * Y
High Battery Voltage Warning Y Under Voltage Warning (L- L, L- N, each Y
High Coolant Temperature Shutdown [ D phase)
High Coolant Temperature Warning Y Weak Cranking Battery Y

High Fuel Level Warning (diesel) * Y Status Messages

High Oil Temperature Shutdown [ D Auto Button Pressed
High Oil Temperature Warning Y EPS Supplying Load
Local Emergency Stop Shutdown [ D Generator Running
Loss ECU Comms Shutdown [ D Generator Started
Loss of Signal Low Coolant Level Voltage Y Generator Stopped
Low Battery Voltage Warning Y GFCI Warning *
Low Coolant Level Shutdown [ D Load Shed Overload
Low Coolant Temperature Warning Y Load Shed Under Frequency
Low Fuel Level Shutdown (diesel) * [ D Off Button Pressed
Low Fuel Level Warning (diesel) * Y RSA Event Programmable Digital Inputs, 1- 8
Low Fuel Pressure Warning (gas) * Y Run Button Pressed
* Function requires optional input sensors or kits
Low Oil Pressure Shutdown [ D
[ Items included with common fault shutdown 10
Low Oil Pressure Warning Y
Low RTC (clock) Battery Voltage Y
Maintenance Reminder1 Y
Maintenance Reminder2 Y
Maintenance Reminder3 Y
Maximum Power Shutdown [ D
Maximum Power Warning Y
Not In Auto Alarm Y
Over Crank Shutdown [ D
Over Current Shutdown (L1, L2, L3) [ D
Over Current Warning (L1, L2, L3) Y
Over Frequency Shutdown [ D
Over Frequency Warning Y
Over Power Shutdown [ D
Over Power Warning Y
Over Speed Shutdown [ D
Over Voltage Shutdown (L- L, L- N, each
phase) [ D
Over Voltage Warning (L- L, L- N, each Y
phase)

G6-162 (APM603) 12/21h Page 4

 John Deere Engine-Powered Models Kohler KD Engine-Powered Models
Inputs and Outputs Inputs and Outputs
Standard Dedicated User Inputs Input Type Standard Dedicated User Inputs Input Type
Auxiliary Fault (Shutdown) Auxiliary Fault (Shutdown)
Auxiliary Warning Auxiliary Warning
Battery Charger Fault Battery Charger Fault
Breaker Closed * Breaker Closed *
Breaker Open * Breaker Tripped/ Open *
Digital Input
Excitation Over Voltage Fuel Leak Alarm
(350 kW and up) Fuel Level Digital Input
Fuel Leak Alarm Idle Switch
Low Fuel Level Switch Key Switch Enable
Remote Emergency Stop Low Fuel Level Switch
Remote Engine Start Two-wire input Low Oil Level
Speed Bias Analog Voltage Input, Remote Emergency Stop
Voltage Bias Scalable up to +/- 10 VDC Remote Reset
Remote Engine Start Two-wire input
Standard Dedicated User Outputs Output Type
Speed Bias Analog Voltage Input,
Close Breaker *
Voltage Bias Scalable up to +/- 10 VDC
Common Failure
Relay Driver Output
Run Standard Dedicated User Outputs Output Type
Trip Breaker / Shunt Trip * Close Breaker *
* Only with remote- mounted electrically operated circuit breakers. Common Failure
Common Warning
Optional Configurable User Inputs and Outputs
EPS Supplying Load
User Configurable Inputs 2 Analog, 0- 5 VDC
4 Dry Contact Digital Generator Running
Relay Driver Output
User Configurable Relay Outputs 14 NO/NC Relays Horn
1 Common Fault Relay Low Coolant Temperature
Note: Programmable I/O is configurable by a Kohler-authorized Not in Auto
technician System Ready
Trip Breaker / Shunt Trip *
JD Engine Data * Only with remote- mounted electrically operated circuit breakers.
The following John Deere engine data is displayed on the APM603
Optional Configurable User Inputs and Outputs
controller.
User Configurable Inputs 16 Dry Contact Digital
Parameter User Configurable Relay Outputs 8 NO/NC Relays
Engine Model Number Note: Programmable I/O is configurable by a Kohler-authorized
Engine Serial Number technician.
ECU Serial Number
KD Engine Data
Coolant Temperature
The following Kohler Diesel engine data is displayed on the APM603
Engine Speed
controller.
Fuel Pressure
Fuel Consumption Rate Parameter
Oil Pressure Engine Model Number
Run Time Hours Engine Serial Number
Ambient Temperature
Charge Air Pressure
Charge Air Temperature
Common Rail Fuel Pressure
Coolant Level
Coolant Temperature
Crankcase Pressure
Engine Speed
Fuel Consumption Rate
Fuel Pressure
Fuel Temperature
Intercooler Coolant Temperature (K175 engines only)
Oil Temperature
Oil Pressure
Run Time Hours

G6-162 (APM603) 12/21h Page 5

 Mitsubishi Engine-Powered Models Volvo Engine-Powered Models
Inputs and Outputs Inputs and Outputs
Standard Dedicated User Inputs Input Type Standard Dedicated User Inputs Input Type
Auxiliary Fault (Shutdown) Auxiliary Fault (Shutdown)
Auxiliary Warning Auxiliary Warning
Battery Charger Fault Battery Charger Fault
Breaker Closed * Breaker Closed *
Breaker Tripped * Breaker Tripped *
Coolant Temperature Coolant Temperature
Emergency Stop, Local Emergency Stop, Local
Emergency Stop, Remote Digital Input Emergency Stop, Remote Digital Input
Excitation Over Voltage Excitation Over Voltage
Fuel Leak Alarm Fuel Leak Alarm
Fuel Level Fuel Level
Ground Fault Relay Ground Fault Relay
Key Switch Auto Key Switch Auto
Key Switch Run Key Switch Run
Low Fuel Level Switch Low Fuel Level Switch
Remote Engine Start Two-wire input Remote Engine Start Two-wire input
Coolant Temperature, Degrees Speed Bias Analog Voltage Input,
Analog Input
Fuel Level % Voltage Bias Scalable up to +/- 10 VDC
Speed Bias Analog Voltage Input,
Voltage Bias Scalable up to +/- 10 VDC Standard Dedicated User Outputs Output Type
Close Breaker *
Standard Dedicated User Outputs Output Type Common Failure
Relay Driver Output
Close Breaker * Run
Common Failure Trip Breaker / Shunt Trip *
Crank * Only with remote- mounted electrically operated circuit breakers.
Relay Driver Output
Horn
Run Optional Configurable User Inputs and Outputs
Trip Breaker / Shunt Trip * User Configurable Inputs 2 Analog, 0- 5 VDC
4 Dry Contact Digital
* Only with remote- mounted electrically operated circuit breakers.
User Configurable Relay Outputs 14 NO/NC Relays
1 Common Fault Relay
Optional Configurable User Inputs and Outputs
Note: Programmable I/O is configurable by a Kohler-authorized
User Configurable Inputs 16 Dry Contact Digital
technician
User Configurable Relay Outputs 8 NO/NC Relays
Note: Programmable I/O is configurable by a Kohler-authorized
technician.
Volvo Engine Data
The following Volvo engine data is displayed on the APM603 controller.
Mitsubishi Engine Data Parameter
The following Mitsubishi engine data is displayed on the APM603 Air Intake Pressure
controller. Air Intake Temperature
Parameter Ambient Temperature
Battery Voltage Barometric Pressure
Coolant Temperature Coolant Temperature
Engine Speed ECU Battery Voltage
Intercooler Temperature (NA on some engine sizes) ECU Runtime Hours
Oil Pressure Engine Speed
Total Run Time Hours Fuel Consumption Rate
Fuel Pressure
Intake Manifold Pressure
Intake Manifold Temperature
Intercooler Temperature
Mechanical Engine Load
Oil Pressure
Oil Temperature

G6-162 (APM603) 12/21h Page 6

 Kohler KG Engine-Powered Models PSI/Doosan Engine-Powered Models
Inputs and Outputs Inputs and Outputs
Standard Dedicated User Inputs Input Type Standard Dedicated User Inputs Input Type
Auxiliary Fault (Shutdown) Auxiliary Fault (Shutdown)
Auxiliary Warning Auxiliary Warning
Battery Charger Fault Battery Charger Fault
Breaker Closed * Breaker Closed *
Breaker Tripped/Open * Breaker Tripped/Open *
Emergency Stop, Local Digital Input Emergency Stop, Local Digital Input
Emergency Stop, Remote Emergency Stop, Remote
Excitation Over Voltage Excitation Over Voltage
Ground Fault Relay Ground Fault Relay
Fuel Type Fuel Type
Low Fuel Pressure Low Fuel Pressure
Remote Engine Start Two-wire input Remote Engine Start Two-wire input
Speed Bias Analog Voltage Input, Speed Bias Analog Voltage Input,
Voltage Bias Scalable up to +/- 10 VDC Voltage Bias Scalable up to +/- 10 VDC

Standard Dedicated User Outputs Output Type Standard Dedicated User Outputs Output Type
Close Breaker * Close Breaker *
Common Failure Common Failure
Common Warning Common Warning
Crank Crank
Relay Driver Output Relay Driver Output
High Coolant Temperature High Coolant Temperature
Horn Horn
Run Run
Trip Breaker / Shunt Trip * Trip Breaker / Shunt Trip *
* Only with remote- mounted electrically operated circuit breakers. * Only with remote- mounted electrically operated circuit breakers.

Optional Configurable User Inputs and Outputs Optional Configurable User Inputs and Outputs
User Configurable Inputs 2 Analog, 0- 5 VDC User Configurable Inputs 2 Analog, 0- 5 VDC
4 Dry Contact Digital 4 Dry Contact Digital
User Configurable Relay Outputs 14 NO/NC Relays User Configurable Relay Outputs 14 NO/NC Relays
1 Common Fault Relay 1 Common Fault Relay
Note: Programmable I/O is configurable by a Kohler-authorized Note: Programmable I/O is configurable by a Kohler-authorized
technician technician
KG Engine Data
The following KG engine data is displayed on the APM603 controller.
PSI/Doosan Engine Data
The following engine data is displayed on the APM603 controller.
Parameter
Coolant Temperature Parameter
ECU Runtime Hours Ambient Temperature
Engine Speed Coolant Temperature
Intake Manifold Pressure ECU Runtime Hours
Intake Manifold Temperature Engine Speed
Intercooler Temperature Intake Manifold Pressure
Fuel Pressure Intake Manifold Temperature
Oil Pressure Intercooler Temperature
Oil Temperature Fuel Pressure
Mechanical Engine Load
Oil Pressure
Oil Temperature

G6-162 (APM603) 12/21h Page 7

 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

APM603 Available Options

- Common Failure Relay provides a relay output to signal a
generator set fault.
- Battery Charger available with 6 amp, 10 amp, and 20 amp output
for 12 and 24V DC voltage output. (Availability is generator model
dependent.) The 10 amp and 20 amp models provide NFPA 110
charging and alarming capability.
- Electrically Operated Circuit Breakers
D For paralleling systems
D Available generator-mounted or remote-mounted
D 24VDC
- Ground Fault Relay provides a relay output to signal a ground fault
is detected.
- Input/Output Module for Kohler Diesel (KD) and Mitsubishi models
provides:
D 16 digital input connections with connection to ground
D 8 relay output connections (Form C, rated 8A, 240 VAC or rated
0.5 A, 48 VDC)
- Input/Output Module for models other than KD or Mitsubishi
provides:
D 2 analog inputs (0- 5 VDC)
D 4 digital input connections with connection to ground
D 14 relay output connections (Form C, rated 10A, 120V)
D 1 common fault relay output (NO, rated 2A, 24VDC)
- Key Switch to allow selection of RUN, OFF and AUTO modes.
Lockable in the AUTO position by removing the key.
- Remote Emergency Stop Switch available as a wall mounted
panel to remotely shut down the generator set.
- Remote Monitoring Panel. The Kohlerr Remote Serial
Annunciator (RSA) enables the operator to monitor the status of the
generator set from a remote location, which may be required for
NFPA 99 and NFPA 110 installations, and up to four Automatic
transfer switches.
- Shunt Trip Wiring provides relay outputs to trip a shunt trip circuit
breaker and to signal the common fault shutdowns. Contacts rated
at 10 amps at 28 VDC or 120 VAC.

DISTRIBUTED BY:

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 Kohlerr generator
set distributor for availability. ¤ 2019 Kohler Co., All rights reserved.

G6-162 (APM603) 12/21h Page 8