Kohler 12RES Installation Manual Download Page 3

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Table of Contents

TP-6514 9/09

Table of Contents 3

Product Identification Information

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Safety Precautions and Instructions

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Introduction

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Service Assistance

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Section 1 Installation

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1.1

General

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1.2

Lifting

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1.3

Generator Set Inspection

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1.4

Location and Mounting

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1.4.1

Exhaust Requirements

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1.4.2

Air Requirements

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1.5

Power Supply

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1.6

Fuel Requirements

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1.6.1

Fuel Supply

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1.6.2

Fuel Pipe Size

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1.7

Fuel Conversion

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1.7.1

Fuel Conversion, 8.5/12 kW

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1.7.2

Fuel Conversion, 17/18 kW

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1.8

Electrical Connections

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1.8.1

AC Connections

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1.8.2

Remote Start Connection

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1.8.3

Grounding

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1.8.4

Battery Charger

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1.9

Battery

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1.10 Accessories

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1.10.1

Common Fault and Auxiliary Run Relay Board

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1.10.2

Carburetor Heater

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1.11 Prestart Installation Check

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1.12 Startup Notification

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1.13 Controller Configuration

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1.13.1

System Parameters

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1.13.2

Application Code Version

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1.14 Voltage and Frequency Adjustments

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1.14.1

Voltage Adjustment

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1.14.2

Frequency Adjustment

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Section 2 Wiring Diagrams

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Appendix A Abbreviations

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Summary of Contents for 12RES

Page 1: ...Residential Commercial Generator Sets Models 8 5 12 17 18RES 12 18TRES Controller Advanced Digital Control ADC RES TP 6514 9 09e Installation ...

Page 2: ...rd the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Controller Identification Record the controller description from the generator set operation man...

Page 3: ...sion 24 1 7 1 Fuel Conversion 8 5 12 kW 25 1 7 2 Fuel Conversion 17 18 kW 26 1 8 Electrical Connections 28 1 8 1 AC Connections 28 1 8 2 Remote Start Connection 30 1 8 3 Grounding 30 1 8 4 Battery Charger 30 1 9 Battery 31 1 10 Accessories 32 1 10 1 Common Fault and Auxiliary Run Relay Board 32 1 10 2 Carburetor Heater 33 1 11 Prestart Installation Check 35 1 12 Startup Notification 35 1 13 Contro...

Page 4: ...TP 6514 9 09 4 Notes ...

Page 5: ...or set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop s...

Page 6: ...risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System Carbon monoxide Can cause severe nausea fainting or death The exhaust sy...

Page 7: ...und because these conditions increase the risk of electrocution Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connect...

Page 8: ...e extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operatingtheheater beforeinstallation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Notice NOTICE Canadian installations only For standby serv...

Page 9: ...atsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual See Figure 1 and Figure 2 for generator set component locations ADV 7466 1 Muffler 2 Oil check 3 Oil fill 4 Air cleaner 5 Fuses 6 RS 232 connector for appl...

Page 10: ...ates 13 Engine starting battery location battery purchased separately 14 Oil drain hose 15 Nameplate location on base 16 Oil drain valve 17 Exhaust 18 Relay board location optional 19 Carburetor heater access opening 20 LP fuel orifice location inside hose fitting 21 Gas regulator assembly 22 DSAI leads 23 Fuel solenoid valve 24 Fuel inlet 25 Air intake 26 Battery cables 27 Battery charger 28 Fiel...

Page 11: ...TP 6514 9 09 11 1 GM66010 1 Emergency stop button 2 Field connection terminal block and circuit breakers 3 Cable inlet area 2 3 Figure 3 Additional Components TRES 3 phase Models ...

Page 12: ...rs Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Off...

Page 13: ... loose or damaged parts or wires Repair or tighten any loose parts before installation 2 Check the engine oil Fill if necessary with the recommended viscosity and grade of oil Use synthetic oil API American Petroleum Institute Service Class SG or higher See TP 6515 Operation Manual for additional information 1 4 Location and Mounting See the dimension drawings on the following pages for the genera...

Page 14: ...TP 6514 9 09 14 Section 1 Installation Figure 1 2 Generator Set Mounting Details and Dimensions 8 5RES 12RES and 12TRES 3 phase ADV 7466 Sheet 1 ...

Page 15: ...TP 6514 9 09 15 Section 1 Installation Figure 1 3 Generator Set Clearances 8 5RES 12RES and 12TRES 3 phase ADV 7466 Sheet 2 ...

Page 16: ...TP 6514 9 09 16 Section 1 Installation Figure 1 4 High Wind Mounting Detail 8 5RES 12RES and 12TRES 3 phase ADV 7466 Sheet 3 ...

Page 17: ...TP 6514 9 09 17 Section 1 Installation Figure 1 5 Generator Set Mounting Details and Dimensions 17RES and 18RES ADV 7341 B Sheet 1 ...

Page 18: ...TP 6514 9 09 18 Section 1 Installation Figure 1 6 Generator Set Clearances 17RES and 18RES ADV 7341 B Sheet 2 ...

Page 19: ...TP 6514 9 09 19 Section 1 Installation Figure 1 7 Generator Set Mounting Details and Dimensions 18TRES 3 phase ADV 7713 Sheet 1 ...

Page 20: ...TP 6514 9 09 20 Section 1 Installation Figure 1 8 Generator Set Clearances 18TRES 3 phase ADV 7713 Sheet 2 ...

Page 21: ... hot exhaust does not blow on plants or other combustible materials Maintain the clearances shown in Figure 1 3 or Figure 1 6 Exhaust System 60 Hz 50 Hz Exhaust flow at rated kW m3 min cfm 8 5 kW 3 3 115 2 7 96 12 kW 3 8 135 3 2 113 17 18 kW 5 3 187 4 4 155 Exhaust gas exiting the enclosure at rated kW _C _F 216 420 Figure 1 9 Exhaust Flow and Temperature 1 4 2 Air Requirements The generator set r...

Page 22: ...riable climates and geographical considerations contact the local fuel supplier for fuel system planning and installation Figure 1 14 lists the recommended fuel ratings and other fuel supply information for natural gas and LP vapor fuels Fuel type Natural Gas LP Vapor Fuel supply inlet 1 2 NPT Fuel supply pressure kPa in H2O 8 5 12 kW 1 3 2 7 5 11 1 7 2 7 7 11 Fuel supply pressure kPa in H2O 17 18...

Page 23: ...68 4 0 141 50 3 6 127 3 0 106 25 2 4 85 2 0 71 LP Vapor m3 hr cfh 100 3 1 108 2 5 89 75 2 5 87 2 0 72 50 1 9 65 1 5 53 25 1 2 44 1 0 36 LP vapor conversion factors 8 58 ft 3 1 lb 0 535 m3 1 kg 36 39 ft 3 1 gal Nominal fuel rating Natural gas 37 MJ m3 1000 Btu ft 3 LP vapor 93 MJ m3 2500 Btu ft 3 Figure 1 16 Fuel Consumption 12 kW Fuel Consumption at load m3 hr cfh 60 Hz 50 Hz Natural Gas m3 hr cfh...

Page 24: ...1 4 Figure 1 20 Fuel Pipe Size 17 18 kW 1 7 Fuel Conversion The multi fuel system allows conversion from natural gas to LP vapor or vice versa in the field while maintaining emissions standard compliance A trained technician or an authorized distributor dealer can convert the fuel system Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the genera...

Page 25: ...ocations 8 5 12 kW Procedure to convert from NG to LP 8 5 12 kW 1 Place the generator set master switch in the OFF position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Turn off the fuel supply 5 Remove the hose clamp and fuel hose from the hose fitting in the fuel block See Figure 1 22 5 tp6195 1 Fuel block 2 Fuel meter...

Page 26: ...stability if necessary See Section 1 14 for instructions 18 Move the generator set master switch to the OFF RESET position to shut down the generator set To convert from LP vapor to natural gas follow the same fuel conversion procedure moving the hose fitting to the natural gas port and plugging the LP port For the 12 kW model connect the DSAI leads for natural gas See Figure 1 23 and Figure 1 24 ...

Page 27: ...econnect the generator set engine starting battery leads negative lead last 12 Reconnect power to the battery charger 13 Start the generator set by moving the generator set master switch to the RUN position 14 Check for leaks using a gas leak detector 15 Run the generator set and check the operation Use the controller to adjust the output and stability if necessary See Section 1 14 for instruction...

Page 28: ...plicable local codes Canadian installations must comply with the Canadian Electrical Code CEC and applicable local codes Ground the generator set from the GRD terminal inside controller compartment according to applicable codes 1 8 1 AC Connections The generator set is equipped with a field connection terminal block located in the air inlet area near the junction box Refer to the decal near the te...

Page 29: ...stall the cover 3 Remove the circuit breaker cover 4 Feed the cables through the openings in the cover and connect the cables Refer to Figure 1 31 and the decal near the terminal block See Section 1 8 3 Grounding and Section 2 Wiring Diagrams 5 Connect the engine start leads from the automatic transfer switch or remote start switch to terminals 3 and 4 on the terminal block See Section 1 8 2 6 Con...

Page 30: ...erly with the neutral either bonded to ground or isolated from ground at the generator Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding of the neutral at the generator NEC 2002 Section 250 20 is one example that has a very good explanation of the neutral grounding requi...

Page 31: ...n avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before discon...

Page 32: ...10 Accessories Have accessories installed by an authorized distributor dealer or a licensed electrician Follow the installation instructions provided with each kit Use separate conduit for AC and DC leads to reduce the possibility of electrical interference Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas Verify that the elect...

Page 33: ...or Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0_C 32_F The carburetor heater prevents condensation and carburetor icing The heater turns on when the temperature at the thermostat falls below approximately 4_C 40_F and turns off when the temperature rises above approximately 16_C 60_F See Figure 1 37 through ...

Page 34: ...rger RES models 3 2 1 Figure 1 38 17 18 kW Carburetor Heater Location air intake side of generator set 1 tp6514 1 Carburetor heater location Figure 1 39 17 18 kW Carburetor Heater Location on Engine bulkhead removed to show heater location GM19463 2 1 Power plug single phase type shown 2 Thermostat 3 Heater 3 8 5 12 kW Carburetor Heater 2 3 17 18 kW Carburetor Heater GM57968 1 1 Figure 1 40 Carbur...

Page 35: ...he generator set 1 12 Startup Notification Complete the startup and installation checklists supplied with the startup notification form Complete and sign the startup notification form and submit copies to Kohler Co and the distributor dealer as instructed on the form Standby systems not registered within 60 days of startup are automatically registered using the manufacturer s ship date as the star...

Page 36: ...n must match the generator set engine type Communication Sleep Mode Setting Cn Available on controllers with application code version 1 13 or higher The communication setting enables or disables J1939 communication and also disables or enables the sleep mode When J1939 communication is enabled the sleep mode is turned off to allow uninterrupted communication with a personal computer running remote...

Page 37: ... controller display changes when the up or down arrow key is pressed X in the runtime hours display above denotes any number from 0 to 9 Press the down arrow key and then the up arrow key 3 times to enter the configuration mode This is the controller password Controller Configuration Mode To SAVE CHANGES To DISCARD CHANGES without saving Y E S Now move the master switch to OFF RESET n o x x x x Pr...

Page 38: ... Digital Control Changes in voltage and speed adjustments are lost if not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved 1 14 1 Voltage Adjustment Note Refer to the flowcharts in Figure 1 46 through Figure 1 48 during the following...

Page 39: ...Refer to the flowcharts in Figure 1 46 through Figure 1 48 during the following procedure Frequency Adjustment Procedure Note Refer to the flowcharts in Figure 1 46 through Figure 1 48 during the following procedure 1 Attach a frequency meter to the AC output leads or an electrical outlet on the load side of the generator set 2 Start and run the generator set until it reaches normal operating temp...

Page 40: ...To raise or lower the voltage stability gain in smaller increments Parameter 2P To enter volts Hz adjustment mode Parameter 3P To raise or lower the volts Hz 00 low 09 high or Hold Wait about 5 seconds until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password x x...

Page 41: ...bility gain fine adjustment mode Parameter 5P To raise or lower the engine governor stability gain in smaller increments 4 P 4 P or or or Continued from Figure 1 46 Press 5 P 5 P Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model S A V E To enter SAVE mode Go t...

Page 42: ...e are 3 options when the display says SAVE Press or To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 1 46 Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours 1 P x x x x x x Figure 1 48 Save Mode ...

Page 43: ...ram ADV 7325 44 8 5 12RES Point to Point Wiring Diagram GM51414 45 17 18RES Schematic Diagram ADV 7353 46 17 18RES Point to Point Wiring Diagram GM52541 47 12TRES 3 phase Schematic Diagram ADV 7623 48 12TRES 3 phase Point to Point Wiring Diagram GM63546 49 18TRES 3 phase Schematic Diagram ADV 7637 50 18TRES 3 phase Point to Point Wiring Diagram GM65661 51 Figure 2 1 Wiring Diagrams and Schematics ...

Page 44: ...TP 6514 9 09 44 Section 2 Wiring Diagrams Figure 2 2 Schematic Diagram Single Phase 8 5 12RES ADV 7325 D ...

Page 45: ...TP 6514 9 09 45 Section 2 Wiring Diagrams Figure 2 3 Point to Point Wiring Diagram Single Phase 8 5 12RES GM51414 C ...

Page 46: ...TP 6514 9 09 46 Section 2 Wiring Diagrams Figure 2 4 Schematic Diagram Single Phase 17 18RES ADV 7353 F ...

Page 47: ...TP 6514 9 09 47 Section 2 Wiring Diagrams Figure 2 5 Point to Point Wiring Diagram Single Phase 17 18RES GM52541 E ...

Page 48: ...TP 6514 9 09 48 Section 2 Wiring Diagrams Figure 2 6 Schematic Diagram Three Phase 12TRES ADV 7623 Sheet 4 ...

Page 49: ...TP 6514 9 09 49 Section 2 Wiring Diagrams Figure 2 7 Point to Point Wiring Diagram Three Phase 12TRES GM63546 Sheet 3 ...

Page 50: ...TP 6514 9 09 50 Section 2 Wiring Diagrams Figure 2 8 Schematic Diagram Three Phase 18TRES ADV 7637 Sheet 3 ...

Page 51: ...TP 6514 9 09 51 Section 2 Wiring Diagrams Figure 2 9 Point toPoint Wiring Diagram Three Phase 18TRES GM65661 Sheet 3 ...

Page 52: ...TP 6514 9 09 52 Section 2 Wiring Diagrams Notes ...

Page 53: ...es cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double pole double ...

Page 54: ... Phillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million PROM programmable read only memory psi pounds per square inch psig pounds per square inch gauge pt pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt quart quarts q...

Page 55: ......

Page 56: ...O Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 ...

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