Kohler 14/20RESAL Installation manual
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Installation
Residential/Commercial Generator Sets
Models:
14/20RESA
14/20RESAL
20RESC
20RESCL
Controllers:
RDC2
DC2
TP-6803 6/15l
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator.
Product Identification Information
Generator Set Identification Numbers
Record 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 manual, spec sheet, or sales invoice.
Controller Description
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup and Registration
Service Assistance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Introduction
1.2
Lifting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Generator Set Inspection
1.4
Location and Mounting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1
Mounting Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2
Concrete Mounting Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3
Exhaust Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5
Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6
Access the Air Intake Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7
Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.1
Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2
Fuel Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.3
Connecting the Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8
Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1
Fuel Conversion, 14RESA/RESAL Equipped with Fuel Block . . . . . . . .
1.8.2
Fuel Conversion, 14RESA/RESAL Equipped with Fuel Orifice Fittings 18
1.8.3
Fuel Conversion, 20RESA/RESAL/RESC/RESCL . . . . . . . . . . . . . . . . . .
20
1.8.4
Regulator Vent Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
14
14
15
15
16
16
1.9
Electrical Connections
1.9.1
Grounding
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9.2
Electrical Lead Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9.3
Field-Connection Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.9.4
AC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 ATS and Accessory Communication Connections
1.10.1
Transfer Switch Connection
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.2
Communication Cable Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.3
System Connections with Accessory Modules . . . . . . . . . . . . . . . . . . . . .
1.11 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 Prestart Installation Check
1.13 Set the Exerciser
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13.1
RDC2 Controller
1.13.2
DC2 Controller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13.3
Loaded Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
34
34
34
34
21
22
22
22
24
25
25
26
26
31
12
12
12
12
12
13
13
11
11
11
Section 2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Programmable Interface Module (PIM)
2.3
Load Management Devices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1
Power Relay Module
2.4
Regulator Heater
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5
Carburetor Heater
2.6
Battery Heater
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7
Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8
OnCue Plus Generator Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9
PowerSync Automatic Paralleling Module (APM) . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
39
41
41
35
36
36
37
42
43
9
9
10
TP-6803 6/15 Table of Contents 3
Table of Contents, continued
Section 3 Drawings and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B Electrical Lead Entry Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
67
69
Table of Contents TP-6803 6/15
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe
personal injury, death, or substantial
property damage.
WARNING
Warning indicates the presence of a hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Safety Precautions and Instructions
Accidental Starting
WARNING
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.
Battery
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause
severe injury or death. Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.
Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
TP-6803 6/15 Safety Precautions and Instructions 5
Battery gases. Explosion can cause
severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, 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 disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
WARNING
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the air cleaner. A sudden backfire can cause severe injury or
death. Do not operate the generator set with the air cleaner removed.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
Catch fuels in an approved container when removing the fuel line or carburetor.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the 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
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause severe nausea,
fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
Carbon monoxide detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according manufacturer’s instructions.
to the
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D
Light-headedness, dizziness
D
Physical fatigue, weakness in joints and muscles
D
Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D
Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
6 Safety Precautions and Instructions TP-6803 6/15
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The fuel system.
Explosive fuel vapors can cause severe injury or death.
Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.
Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Gas fuel leaks.
Explosive fuel vapors can cause severe injury or
death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
Explosive fuel vapors can cause severe injury or death.
following fuels:
Take additional precautions when using the
Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.
TP-6803 6/15
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions.
Hazardous Noise
CAUTION
Hazardous voltage.
Will cause severe injury or death.
This equipment must be installed and serviced by qualified electrical personnel.
WARNING
WARNING
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than
105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards.
Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground 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 connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
Safety Precautions and Instructions 7
Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
Short circuits.
Hazardous voltage/current can cause severe
injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs.
Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.
Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
Heavy Equipment
WARNING
Hot Parts
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the exhaust system. Hot parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system components become 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.
Operating the heater before installation 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 service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
8 Safety Precautions and Instructions TP-6803 6/15
This manual provides installation instructions for
Residential/Commercial Model 14/20RESA/RESAL and 20RESC/RESCL generator sets. See Figure 1.
Refer to TP-6804, Operation Manual, for generator set operation and maintenance instructions.
The generator set is approved for use in stationary applications in locations served by a reliable utility power source.
Kohler strongly recommends that only factoryauthorized distributors or dealers install and service the generator.
Have a Kohlerr authorized distributor/dealer install the generator set outdoors according to the instructions in this manual. The generator set installation must comply with the National Electrical Code (NEC) and local code requirements. Do not install this generator set indoors.
Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
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.
Introduction
List of Related Literature
Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.
Literature Type
Specification Sheet, 20RESA
Specification Sheet, 20RESAL
Specification Sheet, 14RESA
Specification Sheet, 14RESAL
Specification Sheet, 20RESC
Specification Sheet, 20RESCL
Operation Manual, Generator Set
Operation/Installation Manual, Model
RXT Automatic Transfer Switch
Operation/Installation Manual,
Model RDT Transfer Switch
Operation Manual, OnCue Plus
Installation Instructions,
Programmable Interface Module (PIM)
Installation Instructions, Automatic
Paralleling Module (APM)
Installation Instructions,
Load Shed Kit
Installation Instructions,
Concrete Mounting Pads
Installation Instructions,
Power Relay Modules
Figure 2 Related Literature
Part Number
G4-209
G4-210
G4-245
G4-249
G4-246
G4-250
TP-6804
TP-6807
TP-6345
TP-6928
TT-1584
TT-1596
TT--1609
TT--1619
TT--1646
Startup and Registration
When the generator set is installed, complete the startup and installation checklists supplied with the startup notification form. Complete and sign the startup notification form and register the unit using the Kohler online Warranty Processing System.
zaa28533
Figure 1 Generator Set
TP-6803 6/15 9
For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.
D
Consult the Yellow Pages under the heading
Generators—Electric.
D
Visit the Kohler Power Systems website at
KOHLERPower.com.
D
Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product.
D
Call toll free in the US and Canada 1-800-544-2444.
D
Outside the US and Canada, call the nearest regional office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
Service Assistance
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 Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
10 TP-6803 6/15
1.1 Introduction
DANGER
Hazardous voltage.
Will cause severe injury or death.
This equipment must be installed and serviced by qualified electrical personnel.
WARNING
Section 1 Installation
Note: DO NOT install these generator sets inside a building.
Note: Install carbon monoxide (CO) detector(s) on each level of any building adjacent to a generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.
Obtain a building permit and contact your local utility companies to mark the locations of underground pipes and cables.
Read and follow the safety precautions in this manual and observe the decals on the equipment. Refer to the diagrams and drawings in this manual for dimensions and electrical connections during the installation procedure. Read the entire installation procedure and obtain the accessories and tools needed before beginning installation. Perform the steps in the order shown.
To install optional accessories, follow the instructions provided with each kit.
1.2 Lifting
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
Carbon monoxide detectors.
Carbon monoxide can
cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions.
Have the generator set installed by an authorized Kohler distributor/dealer or authorized representative. For all locations, ensure that the installation complies with applicable national and local codes. In the United
States, the installation must comply with the National
Electrical Code (NEC) and local codes. For Canadian installations, refer to the Canadian Electrical Code
(CEC).
The generator set must be installed outdoors. The exhaust systems on enclosed units are designed for outdoor installation only.
TP-6803 6/15
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Model
14RESA/RESAL
20RESA/RESAL
20RESC/RESCL
Figure 1-1 Approximate Weights
Weight, kg (lb.)
191 (420)
243 (535)
243 (535)
Section 1 Installation 11
Approximate generator set weights are shown in
Figure 1-1. Use lifting bars inserted through the holes in the skid to lift the unit. See the dimension drawings in
Section 3 for lifting hole locations.
1.3 Generator Set Inspection
Complete a thorough inspection of the generator set.
Check for the following:
1. Inspect the generator set for 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-6804,
Operation Manual, for additional information.
1.4 Location and Mounting
Install the generator set outdoors near the incoming gas service. The generator set location must allow easy access for maintenance and service. The required distance from a structure is dependent on state and local codes. See the dimension drawing in Section 3 for the minimum clearance from structures and non-combustible materials.
Locate the generator set so that the hot exhaust does not blow on plants or other combustible materials. No plants, shrubs, or other combustible materials are allowed within 1.2 m (4 ft.) of the exhaust end of the generator set.
Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building. Furnace and other similar intakes must be at least 3 m (10 ft.) from the exhaust end of the generator set.
Notice
DO NOT locate the generator set near patios, decks, play areas, or animal shelters. Keep items such as lawn furniture, toys, sports equipment, and all combustible materials away from the generator set exhaust outlet.
Remind family members, children, and visitors to use caution near the generator set. Generator sets connected to automatic transfer switches start automatically during exercise periods and power outages. Some generator set components become hot when the generator set is running and remain hot for a time after the generator set shuts down.
1.4.1
Mounting Area
The generator set is shipped on an engineered composite mounting pad. Prepare a flat, level mounting area covered with a weed barrier and gravel or a concrete mounting pad. Set the composite mounting pad directly on the gravel or concrete.
Do not install the composite mounting pad directly on grass, wood, or other combustible materials. Clear all combustible materials, including plants and shrubs, building materials, and lawn furniture, from an area at least 1.2 m (4 ft.) beyond the exhaust end of the generator set. See the dimension drawing in Section 3.
1.4.2
Concrete Mounting Pads
Kohler Co. offers optional concrete mounting pads that are custom-designed for Model 14RESA/RESAL,
20RESA/RESAL, and 20RESC/RESCL generator sets.
Three-inch and four-inch thick pads are available.
Four-inch pads are recommended for storm-prone areas. See TT-1619 for instructions to install the mounting pad, if necessary.
1.4.3
Exhaust Requirements
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
12 Section 1 Installation TP-6803 6/15
Figure 1-2 gives the exhaust temperature at rated load.
The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure. Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the clearances shown in the dimension drawing in
Section 3.
Exhaust
Exhaust gas exiting the enclosure at rated kW, _C (_F)
Temperature,
_
C (_F)
260 (500)
Figure 1-2 Exhaust Flow and Temperature
The generator set requires correct air flow for cooling and combustion. The inlet and outlet openings in the sound enclosure provide the cooling and combustion air. Figure 1-3 shows the locations of the cooling air intake and exhaust vents. Inspect the air inlet and outlet openings inside and outside the enclosure to ensure that the air flow is not blocked.
1
1
2
1.6 Access the Air Intake Area
The battery, fuel system, and electrical connections are located in the air intake area. Raise the roof and remove the enclosure panel to access the air intake area during installation as described below.
1. Remove two screws from the top of the air intake panel.
Pull the the panel up and off.
See
Figure 1-4.
2. To make the electrical connections, you will also need to remove the cover panel over the terminal block as shown in Section 1.9.3.
3. Reinstall the panels after all electrical connections are complete and the battery is installed and connected.
1
REAR VIEW
1. Air intake
2. Exhaust outlet
Figure 1-3 Cooling Air Intake and Exhaust tp6733
The generator set is designed to operate with all enclosure panels and internal baffling in place. If during installation, maintenance or repair the unit must be operated without the complete enclosure and baffling as shipped from the factory make sure the exhaust panel is removed as well.
1.5 Dimension Drawings
See the dimension drawings in Section 3 for the generator set dimensions, fuel and electric inlet locations, and recommended clearance.
1. Remove 2 screws.
Figure 1-4 Removing the Air Intake Panel
ADV-8424
TP-6803 6/15 Section 1 Installation 13
1.7 Fuel Requirements
The generator set operates using natural gas or LPG fuel. The generator set is EPA-certified for both natural gas and LPG fuels.
The fuel system installation must comply with applicable national, state, and local codes.
WARNING
system planning and installation. Figure 1-5 lists the recommended fuel ratings and other fuel supply information for natural gas and LPG fuels.
Verify that the output pressure from the primary gas utility pressure regulator is within the range shown in
Figure 1-5 and that the utility gas meter flow rate is sufficient to supply the generator set at rated load plus all other gas-consuming appliances. For LPG tanks, verify that the output pressure is as shown in Figure 1-5.
See Figure 1-6 for fuel consumption. Contact the fuel supplier for flow rate information or a gas meter upgrade, if necessary.
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
Explosive fuel vapors can cause severe injury or death.
Take additional precautions when using the following fuels:
Propane (LPG)—Adequate ventilation is mandatory.
Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room.
Inspect the detectors per the manufacturer’s instructions.
Fuel type
Fuel supply inlet
Natural
Gas
1/2 NPT
Fuel supply pressure, kPa (in. H
2
O)
14RESA/RESAL 1.3--2.7
(5--11)
LPG
1.7--2.7
(7--11)
20RESA/RESAL
20RESC/RESCL
1.3--2.7
(5--11)
0.9--2.7
(3.5--11)
1.7--2.7
(7--11)
1.7--2.7
(7--11)
Fuel flow rate, maximum, Btu/hr.:
14RESA/RESAL
20RESA/RESAL
20RESC/RESCL
Nominal Fuel Rating, Btu/ft.
3
Natural gas
LPG
193,000
281,000
281,000
1000
2500
203,000
340,000
340,000
Figure 1-5 Fuel Supply
1.7.1
Fuel Supply
Because of variable climates and geographical considerations, contact the local fuel supplier for fuel
Fuel Type
Natural Gas
LPG
% Load
100%
75%
50%
25%
100%
75%
50%
25%
LPG conversion factors:
8.58 ft.
3 = 1 lb.
0.535 m
36.39 ft.
3
3
= 1 kg
= 1 gal.
Figure 1-6 Fuel Consumption
Fuel Consumption, m 3 /hr. (cfh)
5.4
4.7
3.5
60 Hz
14RESA/RESAL
50 Hz
(193)
(163)
(124)
4.9
4.2
3.1
(175)
(148)
(108)
2.6
2.3
2.1
1.8
(93)
(81)
(75)
(60)
2.4
2.1
1.9
1.5
1.2
(45) 1.1
(40)
Nominal fuel rating:
Natural gas: 37 MJ/m 3 (1000 Btu/ft.
3 )
LPG: 93 MJ/m 3 (2500 Btu/ft.
3 )
(84)
(74)
(68)
(53)
20RESA/RESAL/RESC/RESCL
8.0
6.9
4.6
3.6
3.9
3.1
2.3
1.7
60 Hz
(281)
(243)
(161)
(127)
(136)
(109)
(82)
(59)
6.4
5.4
3.9
2.9
2.9
2.4
1.8
1.3
50 Hz
(225)
(189)
(139)
(103)
(102)
(85)
(63)
(47)
14 Section 1 Installation TP-6803 6/15
1.7.2
Fuel Pipe Size
Ensure that the fuel pipe size and length meet the specifications in Figure 1-7. Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m
(8 ft.) to the measured length for each 90 degree elbow.
Compare the total pipe length with the chart in
Figure 1-7 to find the required pipe size.
Contact local LPG provider for LPG installation information.
Minimum Gas Pipe Size Recommendation, in. NPT
20RESA/RESAL
20RESC/RESCL
Pipe
Length, m (ft.)
8 (25)
14RESA/RESAL
Natural
Gas
(193,000
Btu/hr.)
LPG
(203,000
Btu/hr.)
Natural
Gas
(281,000
Btu/hr.)
LPG
(340,000
Btu/hr.)
15 (50)
30 (100)
46 (150)
61 (200)
3/4
1
1
1 1/4
1 1/4
3/4
3/4
1
1
1
1
1
1 1/4
1 1/4
1 1/4
3/4
1
1
1 1/4
1 1/4
Figure 1-7 Fuel Pipe Size Recommendations
1.7.3
Connecting the Fuel Supply
The dimension drawing in Section 3 shows the location of the fuel inlet connection. Have the fuel supplier install rigid gas piping and a manual fuel shut-off valve. The fuel supply line should line up with the generator set fuel inlet and end about 12 inches away to allow connection with a section of flexible fuel line. Use flexible sections to prevent fuel line breakage caused by vibration.
Note: Do not bend the flexible fuel line to make up for misalignment of the fuel supply line and the generator set fuel inlet.
Apply pipe sealant that is approved for fuel connections.
Hold the fuel solenoid valve with a wrench when tightening the fuel connections.
Note: Do not hold the fuel solenoid valve coil when tightening the fuel connections. See Figure 1-8 for the recommended wrench locations.
1
Note: Do NOT hold the valve coil when tightening connections.
1. Hold valve with wrench on flats of valve body
2. Alternate wrench location
Figure 1-8 Holding Fuel Valve to Tighten Fuel
Connections
IMG_0351
2
Open the manual fuel valves and test all fuel connections using soapy water. If a leak is found, close the fuel valves, clean the fittings, and apply fresh sealant. Check for fuel leaks again with the generator set running.
Protect all fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.
TP-6803 6/15 Section 1 Installation 15
1.8 Fuel Conversion
The multi-fuel system allows conversion from natural gas to LPG (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or an authorized distributor/dealer can convert the fuel system.
After converting the fuel system, change the Fuel Type setting on the controller. See the Operation Manual for instructions to change settings at the controller, or use a personal (laptop) computer and Kohlerr SiteTecht software to change the setting.
Rating Change
Converting the fuel will change the generator set rating.
See the generator set specification sheet for ratings with natural gas and LP. Order a new nameplate with the updated rating and fuel information from an authorized distributor/dealer, if necessary. Provide the following information from the original nameplate:
D
Model Number
D
Spec Number
D
Serial Number
D
Fuel (original and new)
D kW
D kVA
D
Amps
D
Volts
D
Hz
Attach the new nameplate over the old one. Do NOT cover the UL listing information on the old nameplate.
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.
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
Explosive fuel vapors can cause severe injury or death.
Take additional precautions when using the following fuels:
Propane (LPG)—Adequate ventilation is mandatory.
Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room.
Inspect the detectors per the manufacturer’s instructions.
1.8.1
Fuel Conversion, 14RESA/RESAL
Equipped with Fuel Block
Note: Model 14RESA/RESAL generator sets built before June 26, 2014 use a fuel block for the fuel type selection. See Figure 1-9 and use the instructions in this section for fuel conversion.
Model 14RESA/RESAL generators built June 26,
2014, or later are not equipped with the fuel block.
These units use fuel orifice fittings installed in the hose fitting at the fuel regulator. See Section
1.8.2 for fuel conversion instructions.
Two fuel connections on the fuel block allow fieldconversion between natural gas and LPG. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.
Note: Do not adjust the factory-sealed fuel-metering adjustments on the fuel block. Changing the fuelmetering adjustments may violate federal or state laws.
Use the following procedure to convert from natural gas
(NG) to LPG. See Figure 1-9 for the fuel system component locations.
16 Section 1 Installation TP-6803 6/15
Procedure to convert from NG to LPG,
14RESA/RESAL with fuel block
1. Press the OFF button on the generator set controller.
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 1-9.
6. Remove the hose fitting from the natural gas outlet port in the fuel block. See Figure 1-9.
7. Remove the plug from the LP port in the fuel block.
See Figure 1-9.
8. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas outlet port.
9. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP port.
Note: Do not adjust the fuel metering valves.
10. Slide the hose onto the hose fitting and secure it with the clamp.
11. Disconnect digital ignition timing leads 65 and N3 for LPG. The ignition timing leads are located near the fuel solenoid valve. See Figure 1-9.
12. Connect and turn on the new fuel supply.
13. Reconnect the generator set engine starting battery leads, negative (--) lead last.
14. Reconnect power to the battery charger.
15. Start the generator set by pressing the RUN button on the generator set controller.
16. Check for leaks using a gas leak detector.
17. Run the generator set and check the operation.
18. Press the OFF button to to shut down the generator set.
Conversion from LPG to Natural Gas
To convert from LPG to natural gas, follow the fuel conversion procedure above, moving the hose fitting to the natural gas port and plugging the LP port. Connect the DSAI leads for natural gas. See Figure 1-9.
1 2
10 LPG setup shown
9
8
7 6
3
4
5 photo223
Ignition Timing Lead Connection
1. Fuel block
2. Fuel metering valves—factory-sealed, do not adjust
3. Fuel solenoid valve coil
4. Fuel inlet, 1/2 in. NPT
5. Ignition timing leads 65 and N3
6. Recommended holding points for tightening fuel connection
7. Fuel regulator
8. Ports are labeled LP and NG
9. Plug
10. Hose fitting
Figure 1-9 Fuel System, 14RESA/RESAL Equipped with Fuel Block (built before June 26,
2014)
TP-6803 6/15 Section 1 Installation 17
1.8.2
Fuel Conversion, 14RESA/RESAL
Equipped with Fuel Orifice
Fittings
Note: Model 14RESA/RESAL generator sets built before June 26, 2014, use a fuel block for the fuel type selection. See Figure 1-9 and use the instructions Section 1.8.1 for fuel conversion.
Model 14RESA/RESALgenerators built June 26,
2014, or later are not equipped with the fuel block.
These units use fuel orifice fittings installed in the hose fitting at the fuel regulator. See Figure 1-11 and use the instructions in this section for fuel conversion.
For natural gas and LPG fuel, orifice fittings are used in the fuel line. See Figure 1-10. The natural gas orifice fitting is silver in color and stamped NG. The LPG fitting is gold in color and stamped LPG. The fittings are threaded. A straight-blade screwdriver is required to remove and replace the fittings.
NG LPG
1 2
3
Figure 1-10 NG and LPG Fuel Orifice Fittings
The unit is typically shipped set up for natural gas, with the LPG fitting tied near the fuel solenoid valve. To convert to LPG, remove the NG fitting and install the
LPG fitting as described below. See Figure 1-11 for the fuel system component locations.
Procedure to Convert from NG to LPG,
14RESA/RESAL with fuel orifice fittings
1. Press the OFF button on the generator set controller.
2. Disconnect the utility power to the generator.
3. Disconnect the generator set engine starting battery, negative (--) lead first.
4. Turn off and disconnect the fuel supply.
5. Remove the hose clamp and fuel hose from the hose fitting. See Figure 1-11.
Ignition Timing Lead Connection
1. LPG fitting tied to bracket for shipping
2. Fuel hose and clamp
3. Ignition timing leads
Figure 1-11 Fuel System, As Shipped (Model
14RESA/RESAL built after June 26,
2014)
6. Use a straight-blade screwdriver to remove the NG orifice from the hose fitting. See Figure 1-12.
7. Insert the LPG orifice into the hose fitting. Use a straight-blade screwdriver to tighten the fitting until it is snug.
8. Slide the hose onto the hose fitting and secure it with the clamp.
9. Disconnect ignition timing leads 65 and N3 for
LPG. The ignition timing leads are located near the fuel solenoid valve. See Figure 1-11.
18 Section 1 Installation TP-6803 6/15
10. Connect and turn on the new fuel supply.
11. Reconnect the generator set engine starting battery leads, negative (--) lead last.
12. Reconnect the utility power to the generator.
13. Start the generator set by pressing the RUN button on the generator set controller.
14. Check for leaks using a gas leak detector.
15. Run the generator set and check the operation.
16. Press the OFF button to shut down the generator set.
Conversion from LPG to Natural Gas
To convert from LPG to natural gas, repeat the steps above, removing the LPG fuel orifice and installing the
NG fitting. Connect ignition timing leads 65 and N3 together for natural gas.
1
2
ORIFICE FITTING DETAIL
1. Orifice fitting (see detail)
2. Hose barb fitting
Figure 1-12 14RESA/RESAL Fuel System Showing Orifice Fittings (generators built after June 26, 2014)
GM84143
TP-6803 6/15 Section 1 Installation 19
1.8.3
Fuel Conversion,
20RESA/RESAL/RESC/RESCL
For LPG fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve. To convert to
LPG, install the LPG orifice as described below. See
Figure 1-13 for the fuel system component locations.
Note: The generator set harness may contain a pair of ignition timing leads near the fuel solenoid valve.
Connecting or disconnecting these leads has no effect on the 20RESA/RESAL/RESC/RESCL operation.
Procedure to Convert from NG to LPG,
20RESA/RESAL/RESC/RESCL
1. Press the OFF button on the generator set controller.
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. See Figure 1-13.
6. Insert the LPG orifice into the hose fitting. See
Figure 1-13.
7. Slide the hose onto the hose fitting and secure it with the clamp.
8. Connect and turn on the new fuel supply.
9. Reconnect the generator set engine starting battery leads, negative (--) lead last.
10. Reconnect power to the battery charger.
11. Start the generator set by pressing the RUN button on the generator set controller.
12. Check for leaks using a gas leak detector.
13. Run the generator set and check the operation.
14. Press the OFF button to shut down the generator set.
Conversion from LPG to Natural Gas
To convert from LPG to natural gas, repeat the steps above to remove the LPG fuel orifice.
LPG setup shown
1
2
3
1. LPG orifice 4
GM84143
2. Hose fitting
3. Regulator
4. Regulator vent tubes (vent to the outside of the controller)
Figure 1-13 Fuel Regulator and LPG Orifice,
20RESA/RESAL/RESC/RESCL
1.8.4
Regulator Vent Hose
Model 20RESA/RESAL/RESC/RESCL generators are equipped with fuel regulator vent hoses. Drill or punch two holes in the enclosure at the locations shown on the template in Appendix B. It may be convenient to cut openings for the electrical leads at the same time as shown on the template and in Section 1.9.2.
Insert the open ends of the hoses through the holes to the outside of the enclosure as shown in Figure 1-14.
1
2 sb722
1. Fuel regulator vent tubes, qty. 2
2. Drill or punch two holes and route both hoses to the outside of the enclosure
Figure 1-14 Fuel Regulator Vent Hoses
20 Section 1 Installation TP-6803 6/15
1.9 Electrical Connections
DANGER
Hazardous voltage.
Will cause severe injury or death.
This equipment must be installed and serviced by qualified electrical personnel.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
Electrical backfeed to the utility. Hazardous backfeed
voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
NOTICE
Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.
Have an authorized distributor/dealer or a licensed electrician make the following electrical connections.
The electrical installation must comply with the National
Electrical Coder (NEC) class 1 wire designation and all applicable local codes. Canadian installations must comply with the Canadian Electrical Code (CEC) and applicable local codes.
AC circuit protection. All AC circuits must include circuit breaker or fuse protection. The circuit breaker must be rated for a maximum of 125% of the rated generator set output current. The circuit breaker must open all ungrounded connectors. The generator set is equipped with a factory-installed circuit breaker.
For customer-supplied wiring, select the wire temperature rating in Figure 1-15 based upon the following criteria:
D
Select row 1, 2, 3, or 4 if the circuit rating is
110 amperes or less or requires #1 AWG (42.4 mm or smaller conductors.
2 )
D
Select row 3 or 4 if the circuit rating is greater than
110 amperes or requires #1 AWG (42.4 mm larger conductors.
2 ) or
Row Temp. Rating Copper (Cu) Only
1 60_C (140_F) or
75_C (167_F)
Use No. * AWG, 60_C wire or use No. * AWG, 75_C wire
2
3
60_C (140_F)
75_C (167_F)
Use No. * AWG, 60_C wire
Use No. *[ AWG, 75_C wire
Cu/Aluminum (Al) Combinations
Use 60_C wire, either No. * AWG Cu, or No. *
AWG Al or use 75_C wire, either No. * AWG
Cu or No. * AWG Al
Use 60_C wire, either No. * AWG Cu or No. *
AWG Al
Use 75_C wire, either No. *[ AWG Cu or No.
*[ AWG Al
Al Only
Use 60_C wire, No. * AWG or use 75_C wire, No. * AWG
Use 60_C wire, No. * AWG
Use 75_C wire, No.*[ AWG
4 90_C (194_F) Use No. *[ AWG, 90_C wire Use 90_C wire, either No. *[ AWG Cu or No.
*[ AWG Al
Use 90_C wire, No.*[ AWG
* The wire size for 60_C (140_F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for the wire given in Table 310-16 of the National Electrical Coder, in ANSI/NFPA 70, and on 115% of the maximum current that the circuit carries under rated conditions. The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
[ Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the guidelines in the preceding footnote.
Figure 1-15 Terminal Markings for Various Temperature Ratings and Conductors
The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
TP-6803 6/15 Section 1 Installation 21
1.9.1
Grounding
Ground the generator set. The grounding method
must comply with NEC and local codes. Connect the grounding cable to the generator set ground terminal
GND on the field-connection terminal block.
Generator sets are shipped with the generator neutral bonded (connected) to the generator ground in the junction box. The requirement for having a bonded
(grounded) neutral or ungrounded neutral is determined by the type of installation. At installation, the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the generator. The generator set will operate properly 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
Section 250 is one example that has a very good explanation of the neutral grounding requirements for generators.
1.9.2
Electrical Lead Entry
Drill or punch holes in the enclosure for the electrical conduit in the locations shown in Figure 1-16.
A full-scale dimensioned template for the hole locations is printed in Appendix B. See page 69.
1
2 3
1.9.3
Field-Connection Terminal Block
The generator set is equipped with a field-connection terminal block located in the air intake area near the junction box. Leads have been factory-installed from the junction box to the terminal block for easy field wiring.
See Figure 1-17 for the terminal block location.
Remove the cover panel for access to the field connections.
1 adv-8424
1. Cover panel. Remove for access to field-connection terminal block.
Figure 1-17 Field-Connection Terminal Block
Location
5
ADV--8424
4
Note: See Appendix B for a full-scale template with dimensions.
1. Optional emergency stop switch location. Do not use to route wiring.
2. Utility voltage electrical lead entry point (drill or punch)
3. Do not drill holes in this part of the panel
4. ATS signal electrical lead entry point (drill or punch)
5. 1/2 NPT female fuel inlet
Figure 1-16 Electrical Lead Entry Locations
22 Section 1 Installation TP-6803 6/15
See Figure 1-18 for terminal block details. Refer to the terminal block decal shown in Figure 1-19 for connections and cable sizes. Also see the wiring diagram in Section 3.
Route AC leads through flexible conduit. Ensure that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Route low-voltage communication leads through separate conduit.
Procedure
1. Drill holes for the conduit fittings. See Figure 1-16 and Appendix B for the recommended electrical inlet locations.
Feed the cables through the openings.
2. Connect the leads from the transfer switch emergency source lugs to the L1, L2, and L3 connections on the generator set terminal block as applicable for single or three-phase applications.
See Figure 1-18 and Figure 1-19.
3. Connect the neutral (L0) and ground (GRD) leads from the ATS and the main panel to the corresponding connection points on the terminal block. See Section 1.9.1, Grounding.
4. Connect AC power source leads to the terminal block connections labeled LINE, NEUTRAL and
GROUND. Connect the circuit to the load side of the transfer switch. See Section 1.9.4 for more information about the AC power requirement.
Note: AC power must be connected to maintain the charge on the engine starting battery.
5. For connection of optional transfer switches, the programmable interface module (PIM), and/or a load shed kit, see Section 1.10.1.
Note: The ground lug near the terminal block
(item 3 in Figure 1-18) is used to connect the shield on the communication cable for the accessories.
6. If the OnCuer Plus Generator Management
System will be used with the generator set, run category 5E network cable from the generator set to the customer’s router or modem.
Note: The OnCue Plus Wireless kit allows connection of the generator controller to the customer’s wireless router without running a network cable from the generator to the customer’s router or modem. If the OnCue
Plus Wireless is used, follow the instructions provided with the kit to install and set up the wireless kit and proceed to step 7.
TP-6803 6/15 a. Route the network cable with other low-voltage signal wiring (for example, the RBUS communication leads or engine start leads to the transfer switch), in separate conduit from the AC load leads. If the network cable is longer than 100 meters (328 ft.), use a repeater or switch.
b. Use an RJ45 inline coupler to connect the
Ethernet cable to the cable in the customer connection box. See Figure 1-18. The inline coupler is included with the OnCue Plus kit.
7. When connections to the terminal block are complete, replace the cover plate.
3
4
2
5
6
7
1
GM84094
Note: The number of terminals varies for 1-phase and 3-phase models. See Figure 1-19.
1. Low voltage RBUS communication to RXT ATS, PIM, load shed kit, and/or APM.
2. Engine start connections from transfer switches other than the RXT, if used.
3. Ground connection for communication cable shield
4. Ethernet cable for optional OnCue Plus connection
5. AC load connections
6. AC power connections required for battery charging and accessories
7. Connection decal; see Figure 1-19.
Figure 1-18 Field Connection Terminal Blocks
Section 1 Installation 23
1-Phase, 1-Pole Circuit Breaker
1-Phase, 2-Pole Circuit Breaker
1.9.4
AC Power Supply
The installer must connect AC power for the battery charger (which is integral to the RDC2 controller) and the optional accessories shown in Figure 1-20. The power source must comply with state and local codes.
The power to the battery charger and accessories must be backed up by the generator so that power is available at all times.
Be sure to disconnect power at the distribution panel before making the connections. Connect power leads to the AC power connection points labeled LINE,
NEUTRAL, and GROUND on the field-connection terminal block. Connect the circuit to the load side of the transfer switch so that it is backed up by the generator.
See Figure 1-18 and the wiring diagrams in Section 3 for connection details.
Equipment
Battery charger
(standard)
Carburetor heater
(optional)
Battery heater (optional)
Power Requirement, Max.
Watts Volts at 50/60 Hz
50
50
37
100--120 VAC
200--250 VAC
100--120 VAC
200--250 VAC 37
50
50
100--120 VAC
200--250 VAC
Fuel regulator heater
(optional; available for
20RESA/RESAL/RESC/
RESCL only)
60
100
Figure 1-20 Power Requirements
100--120 VAC
200--250 VAC
3-Phase
Figure 1-19 Terminal Block Connection Decals
24 Section 1 Installation TP-6803 6/15
1.10 ATS and Accessory
Communication Connections
The following sections cover communication connections from the generator set to automatic transfer switches and RBUS accessories, including the programmable interface module (PIM) and the load shed kit.
1.10.1 Transfer Switch Connection
Connect the ATS or remote start/stop switch. Connect the load leads from the generator set to the Emergency source lugs on the ATS.
Route low-voltage communication leads through separate conduit from the
AC power and load leads. All connections must comply with applicable state and local codes.
Note: Do not use the Kohlerr Model RRT transfer switch with the RESA/RESAL or RESC/RESCL generator sets covered in this document.
1
2
Generator Set
GND
Communication connections for a Model RXT transfer switch
One Model RXT transfer switch can be connected to the generator set.
See Figure 1-21.
Use shielded, twisted-pair communication cable to connect P10-1 through P10-4 on the transfer switch interface module to the generator set terminal block connections A, B, PWR, and COM. See Section 1.10.2 for the communication cable recommendations and maximum cable length.
Note: Connections 3 and 4 on the generator set are not used with the Model RXT transfer switch.
Engine start connection for other transfer switches or a remote start/stop switch
Connect the engine start leads from the transfer switch or remote start switch to terminals 3 and 4 on the terminal block. See Figure 1-22. Route the engine start leads through separate conduit from the AC power and load leads.
RBUS
12 VDC
A
B
PWR
COM
4
3
A
B
PWR
COM
3
4
A
B
PWR
COM
4
RXT*
Note: Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS.
* RXT transfer switch with standard or combined interface/ load management board.
1. Generator set terminal block. See Figure 1-17 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable. See Section 1.10.2, Cable Specifications.
4. Leave one end of each cable shield disconnected. If accessory modules (PIM or load shed kit) are connected, see Section 1.10.3.
Figure 1-21 Model RXT Transfer Switch Communication Connection to Generator Set Terminal Block
TP-6803 6/15 Section 1 Installation 25
Generator Set
1
A
B
PWR
COM
4
3
2 ATS
(with engine start contacts) tp6803
1. Generator Set Terminal Block. See the dimension drawings in Section 3 for location. Check the decal on the generator set for terminal block connections.
2. Engine start leads 3 and 4. See the ATS manual for cable size specifications.
Figure 1-22 Engine Start Connections with Transfer Switch Models other than Model RXT
1.10.2 Communication Cable
Specifications
RBUS Connections A and B
For the RBUS communication connections A and B to the optional RBUS modules, use 20 AWG shielded, twisted-pair communication cable.
Belden #9402
(two-pair) or Belden #8762 (single-pair) or equivalent cable is recommended. Optional RBUS modules can include the Model RXT transfer switch, RXT combined interface/load management board, automatic paralleling module (APM), programmable interface module (PIM), and/or the load shed kit for the RDT or
RXT transfer switch.
For outdoor installations, including those with buried cables and/or conduit, use outdoor-rated Belden
#1075A or equivalent 20 AWG shielded, twisted-pair communication cable.
PWR and COM Connections
For the PWR and COM connections, the cable size and maximum cable length depends on the number of modules connected. See Figure 1-23.
D
For short cable runs shown in the first two rows of
Figure 1-23, use one pair in the two-pair communication cable for the A and B connections, and use the second pair for the PWR and COM connections.
D
For the longer cable runs shown in the last two rows of
Figure 1-23, use 12 or 14 AWG cable for PWR and
COM, and use the 20 AWG communication cable specified above for the A and B connections only. In this case, single-pair communication cable such as
Belden #8762 can be used for the A and B connections.
1.10.3 System Connections with
Accessory Modules
See Figure 1-24 through Figure 1-28 for connection options to RBUS accessory modules. Note the cable shield connections shown in Figure 1-24.
Note: Refer to the installation instructions provided with the automatic paralleling module (APM) for
RBUS connections to the APM.
The maximum cable length depends on the number of
RBUS modules connected. See Figure 1-23 for the maximum cable lengths with 1, to 4 modules per cable run.
Note: A model RXT transfer switch with combined interface/load management board acts as two
RBUS modules: one RXT transfer switch and one load management device.
Power Relay Modules are not RBUS modules and do not add to the number of modules in Figure 1-23.
26 Section 1 Installation TP-6803 6/15
Maximum length per run, meters (ft.)
Number of Modules (RXT, APM, PIM, and/or load management device) per Run
Cable (TB1--PWR and COM)
Belden #9402 or equivalent 20AWG for indoor installations
1 Module
46 (150)
2 Modules
15 (50)
3 Modules
5 (17)
4 Modules
Do not use 20AWG for PWR and COM
Belden #1075A or equivalent 20AWG for outdoor installations or buried cables
14 AWG *
46 (150)
137 (450)
15 (50)
137 (450)
5 (17)
107 (350)
Do not use 20AWG for PWR and COM
107 (350)
12 AWG * 137 (450) 137 (450) 137 (450) 137 (450)
* Use 12 or 14 AWG cable for PWR and COM connections only. For RBUS connections A and B, use shielded, twisted pair communication cable specified above.
Figure 1-23 Total Cable Lengths for PWR and COM Connections
2
4
3 GND
Generator Set
RBUS
12 VDC
A
B
PWR
COM
4
3
A
B
PWR
COM
A
B
PWR
COM
RXT*
A
B
PWR
COM
1
A
B
PWR
COM
PIM
A
B
PWR
COM
5
A
B
PWR
COM
Load
Shed
Kit
Note: Connect A to A, B to B, PWR to PWR, and COM to COM.
See Section 1.10.2, Cable Specifications.
5
* RXT transfer switch with standard or combined interface/ load management board.
Do not use a load shed kit with a combined interface board.
1. Generator set terminal block. See Figure 1-17 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable.
4. Connect shields together as shown.
5. Leave one end of each cable shield disconnected at the last device.
Figure 1-24 Accessory Module Communication Connection Details
TP-6803 6/15 Section 1 Installation 27
GND
Generator Set
RBUS
12 VDC
A
B
PWR
COM
4
3
A
B
PWR
COM
6
1
2
3
A
B
PWR
COM
4
RXT*
A
B
PWR
COM
A
B
PWR
COM
PIM
A
B
PWR
COM
5
A
B
PWR
COM
Load
Shed
Kit
Note: Connect A to A, B to B, PWR to PWR, and COM to COM.
See Section 1.10.2, Cable Specifications.
* RXT transfer switch with standard or combined interface/ load management board.
Do not use a load shed kit with a combined interface board.
1. Generator set terminal block. See Figure 1-17 for location. Check the decal on the generator set for terminal block connections.
2. Connect one end of each cable shield to GROUND at the generator set.
3. Communication cable Belden #8762 or equivalent 20 AWG shielded, twisted-pair cable (one pair).
4. Connect shields together as shown.
5. Leave one end of each cable shield disconnected at the last device.
6. 12 AWG or 14 AWG leads for PWR and COM.
Figure 1-25 Accessory Module Connections with 12--14 AWG Power Leads
28 Section 1 Installation TP-6803 6/15
Generator Set
Terminal
Block
RXT ATS
Notes:
D
See Figure 1-17 for terminal block location on generator set.
Check the decal on the generator set for terminal block connections.
D
See Section 1.10.2, Cable Specifications (3 runs with 1 module each shown).
D
See Figure 1-24 for communication connection detail (A and B,
PWR and COM).
D
Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 1-27.
Figure 1-26 Accessory Module Connections (three cable runs with one module each)
Load
Shed
Kit
PIM tp6803
3
1
Generator Set
RBUS
12 VDC
A
B
PWR
COM
4
3
2
3
A
B
PWR
COM
SHIELDED
CABLE
A
B
PWR
COM
SHIELDED
CABLE tp6803
1. Generator Set Terminal Block. See the dimension drawings in Section 3 for location. Check the decal on the generator set for terminal block connections.
2. Splice.
3. Connect all of the shield leads on this end to GROUND at the generator set.
Figure 1-27 Multiple Connections to the Generator Set
TP-6803 6/15 Section 1 Installation 29
Generator Set
Terminal
Block
RXT ATS
Notes:
D
See Figure 1-17 for terminal block location on generator set. Check the decal on the generator set for terminal block connections.
D
See Section 1.10.2, Cable Specifications.
D
See Figure 1-24 for communication connection detail (A and B, PWR and COM).
Connect the cable shield to ground at the generator set.
D
Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See
Figure 1-27.
PIM
Load
Shed
Kit
Figure 1-28 Accessory Module Connections (two cable runs with one and two modules shown) tp6809
30 Section 1 Installation TP-6803 6/15
1.11 Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, 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 disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
TP-6803 6/15 Section 1 Installation 31
Battery Description
Starting batteries are usually the lead-acid type. Use a
12-volt group 51 battery with a minimum rating of 500 cold cranking amps at 0_F. The generator set uses a negative ground with a 12-volt engine electrical system.
See Figure 1-29 for battery connections. Make sure that the battery is correctly connected and the terminals are tight.
Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse.
See the dimension drawing in Section 3 for the engine starting battery location on the air intake side of the generator set. Standard battery cables provide easy connection to the battery.
1 2
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor.
Figure 1-29 Typical Battery Connection
Use the following procedure to install and connect the battery.
Battery Installation Procedure
1. Ensure that the starting battery is fully charged before placing the battery in service.
2. Clean the battery posts and/or adapters if necessary.
3. Install the battery post adapters, if needed.
4. Place the battery in the housing.
5. Connect the positive (+) lead to the engine starting battery.
6. Connect the negative (--) lead to the engine starting battery.
Refer to the generator set operation manual and the battery manufacturer’s instructions for battery maintenance instructions.
When power is applied to the RDC2/DC2 controller (that is, when the battery is connected), you will be prompted to set the date and time, and then to set the exerciser.
See Section 1.13 and the generator set operation manual for instructions.
If the battery is disconnected for service or replacement, the exercise settings on the RDC2/DC2 controller are lost. Set the exerciser after installing and connecting the battery. See Section 1.13, Set Exerciser.
32 Section 1 Installation TP-6803 6/15
1.12 Prestart Installation Check
WARNING
Hazardous voltage.
Moving parts.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
Carbon monoxide symptoms. Carbon monoxide can
cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
D
Light-headedness, dizziness
D
Physical fatigue, weakness in joints and muscles
D
Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D
Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following Prestart
Checklist.
Prestart Checklist
Air Cleaner. Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine. See the generator set operation manual for instructions.
Air Inlets. Check for clean and unobstructed air inlets.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.
Enclosure.
Check that all enclosure panels and internal baffling are in place.
Exhaust System.
Check for exhaust leaks and blockages. Check the muffler condition.
D
Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections.
D
Check for corroded or broken metal parts and replace them as needed.
D
Check that the exhaust outlet is unobstructed.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
TP-6803 6/15 Section 1 Installation 33
1.13 Set the Exerciser
Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks. See the generator set Operation Manual for detailed descriptions of the exercise operation.
1.13.1 RDC2 Controller
When power is applied to the RDC2 controller (when the battery or the utility power for the battery charger is connected), you will be prompted to set the date and time, and then to set the exerciser.
The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. Repeat until the date, time, and exercise are set and the controller display shows the main menu. See the generator set Operation
Manual for more detailed instructions to set the date and time and set the exerciser.
Press AUTO to place the generator set controller into automatic mode.
1.13.2 DC2 Controller
To set the exerciser on the DC2 controller, first press
AUTO to place the controller into automatic (standby) mode. Then press and hold the Exercise button. The generator set will start and run a 20-minute unloaded cycle exercise. The generator set will run automatically for 20 minutes at the same time every 7 days. See the generator set Operation Manual for more information.
1.13.3 Loaded Exercise
In order to set a loaded exercise using the RDC2 or DC2 controller, a Kohlerr Model RXT transfer switch must be connected. See the generator set operation manual for instructions to set a loaded exercise.
To set a loaded exercise on a generator set connected to a transfer switch other than a Model RXT, use the transfer switch controller to set the exercise. Refer to the transfer switch operation manual for instructions.
Date:
05Dec2011
Setting will flash.
Press the up and down arrow buttons to change the setting.
Press Select to save the setting.
Time:
08:31am
Next Exercise:
08:31a 12Dec2011 tp6803
Figure 1-30 Set Time, Date, and Exercise (RDC2)
34 Section 1 Installation TP-6803 6/15
Section 2 Accessories
2.1 Introduction
This section describes some of the accessories that are available for the generator sets. Have accessories installed by an authorized distributor/dealer or a licensed electrician. This document does not contain installation instructions for accessories.
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 electrical installation complies with the National
Electrical Code (NEC) and all applicable local codes.
See the wiring diagrams in Section 3 for more information regarding generator set electrical connections.
2.2 Programmable Interface
Module (PIM)
The optional programmable interface module (PIM) provides two programmable inputs and six dry contact outputs, four of which are programmable. See TT-1584 for PIM installation and connection instructions. Also see Section 1.10 of this manual for connection to the generator set.
The default settings for the inputs and outputs are shown in Figure 2-2. To change the input and output settings, use a personal computer running Kohlerr
SiteTecht software. See TP-6701, SiteTech Software
Operation Manual, for instructions.
KohlerOnCuer Plus can be used to actively control PIM outputs. See the OnCue Plus Operation Manual for instructions.
1
2
3
1
1
ADV-8199
1. Output connections (3 terminal blocks, 6 outputs)
2. Input connections (2 inputs)
3. RBUS communication connection to generator set terminal block TB2
Figure 2-1 Optional PIM
PIM Connection
Input 1
Input 2
Output 1 (Relay 1)
Output 2 (Relay 2)
Output 3 (Relay 3)
Output 4 (Relay 4)
Output 5 (Relay 5)
Output 6 (Relay 6)
Factory Default Setting
None
None
Run
Common Fault
Low Battery Voltage
(Programmable)
Not in Auto (Programmable)
Cooldown (Programmable)
Normal Source Failure
(Programmable)
Figure 2-2 PIM Inputs and Outputs
TP-6803 6/15 Section 2 Accessories 35
2.3 Load Management Devices
Two optional load management devices are available for use with single-phase generator sets and a model
RXT or RDT transfer switch:
D
The optional Load Shed Kit mounts inside a Model
RDT or RXT transfer switch. Figure 2-3 shows the load shed assembly.
D
The combined interface/load management board is available for the Model RXT transfer switch.
The devices provide an automatic load management system to comply with Section 702.5 of NEC 2008. The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes.
Note: The load management devices are only compatible with single-phase generator sets.
With a load management system, less critical appliances can be powered by the generator set when the more important appliances are not running, allowing the use of a smaller generator set than would be needed to run all of the building’s electrical equipment at the same time.
The load shed kit automatically manages up to six residential loads:
D
Up to four normally closed power relays can be connected through normally open relay contacts on the circuit board. See the load shed kit installation instructions for relay specifications. Kohlerr Power
Relay Modules are recomended.
D
Two relays are included on the load management device to control two independent heating, ventilation, and air conditioning (HVAC) loads.
Note: Connect only non-essential loads to the load shed kit.
The load management device receives commands from the RDC2 or DC2 generator controller and energizes or de-energizes the appropriate load relays to add or shed non-critical loads according to their priority.
An adequate electrical supply is required for operation of the customer-supplied power relays connected to the load shed kit. Check the electrical requirements of the customer-provided equipment prior to installation to determine the wire size and circuit protection required.
Verify that customer-provided equipment complies with applicable local and national electrical codes.
For detailed installation and connection instructions, see the installation instructions provided with the load shed kit or the Operation/Installation Manual for the
Model RXT transfer switch.
1
3
1. Terminal block TB10
2. Load control circuit board
3. Mounting bracket
GM88281
Note: Kit includes current transformer (CT), not shown.
Figure 2-3 Load Shed Assembly GM88281-1
(mounts inside the transfer switch enclosure)
2.3.1
Power Relay Module
The power relay module kit contains one 50 amp normally closed relay with connecting lugs in a NEMA type 3R enclosure. Connect up to four (4) power relay modules to the load management devices listed above.
The power relay modules can be mounted indoors or outdoors. Two (2) 120 VAC loads (shed simultaneously) or a single 240 VAC load can be wired to each relay.
For detailed installation and connection instructions, see the installation instructions provided with the power relay module kit.
Figure 2-4 Power Relay Module
2
36 Section 2 Accessories TP-6803 6/15
2.4 Regulator Heater
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the engine heater. Hot parts can cause minor
personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage.
Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.
The optional regulator heater kit is designed for Model
20RESA/RESC and 20RESAL/RESCL generator sets.
The regulator heater kit is recommended in addition to the carburetor heater for reliable engine starting in temperatures below --18_C (0_F). See Figure 2-5 for heater specifications. Order the 120 V or 240 V kit as appropriate for your application. See specification sheet G6-126 for kit details.
Heater rating
Thermostat
Pad diameter
Cord length
120 V Kit
120 VAC, 60 W
50/60 Hz
240 V Kit
240 V, 100W
50/60 Hz
4 _ C/13 _ C ( 40 _ F/55 _ F) Snap action
127 mm (5 in.)
610 mm (24 in.)
Figure 2-5 Regulator Heater Specifications
The fuel regulator heater is a 127 mm (5 in.) diameter round heating pad with a snap action thermostat and a power cord. Figure 2-6 and Figure 2-7 show the heater installed on the fuel regulator, which is located on the air intake side of the generator set. To install the regulator heater kit, follow the instructions in TT-1569, provided with the kit.
The fuel regulator heater requires a source of AC power.
Verify that AC power is connected to the generator set as described in Section 1.9. The circuit must be backed up by the generator set to provide power at all times.
120 VAC generator sets are equipped with one or two
120 VAC receptacles. Use an adapter or splitter to connect more than one accessory to the receptacle.
240 volt heater kits use a 3-pin power connector.
Generator sets built after 10/9/2013 with serial numbers
SGM327VFJ or later have a knockout under the controller for the 240 VAC power connector. 240 volt fuel regulator heater kits include an adapter harness to allow connection of two AC accessories.
1
2
Knockout Detail
GM79141-E
Note: Adapter harness for multiple accessories not shown.
1. 240 VAC power connection (see knockout detail)
2. Fuel regulator heater pad
Figure 2-6 Model 20RESA/RESAL/RESC/RESCL
240 Volt Kit Power Connection
TP-6803 6/15 Section 2 Accessories 37
1
1. Fuel regulator heater pad
2. Receptacle with adapter (120 VAC kits)
Note: See Figure 2-6 for 240 volt power connection.
Figure 2-7 Installed Regulator Heater Kit (for 20RESA/RESAL/RESC/RESCL)
2
GM79141C
38 Section 2 Accessories TP-6803 6/15
2.5 Carburetor Heater
WARNING
1
2
3
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the engine heater. Hot parts can cause minor
personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage.
Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.
A 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).
The carburetor heaters are shown in Figure 2-9.
To install the carburetor heater, follow the instructions provided with the kit. Figure 2-10 shows the installed carburetor heater kit installed for a 14 kW generator set.
Figure 2-11 shows the location for the carburetor heater kit on a 20 kW generator set.
Verify that AC power is connected to the generator set as described in Section 1.9. The circuit must be backed up by the generator set to provide power at all times.
The heater thermostat is installed in the cord.
Figure 2-9 shows the location of the thermostat on the power cord. The heater power cord and thermostat are located in the generator set housing air intake area/ battery compartment.
For 120 volt models, plug the carburetor heater into one of the 120 VAC receptacles provided.
240 volt kits use a 3-pin power connector. Generator sets built after 10/9/2013 have a knockout in the bulkhead for the 240 VAC power connector.
See
Figure 2-12.
Kit Number
Voltage
120 Volt Kits
120 VAC
50/60 Hz
240 Volt Kits
240 VAC/60 Hz
230 VAC/50 Hz
Thermostat ON
Thermostat OFF
4 ± 4_C (40 ± 7_F)
16 ± 3_C (60 ± 5_F)
Figure 2-8 Carburetor Heater Specifications
TP-6803 6/15
1
Carburetor Heater for 14 kW Models
GM19463
1
2
1. Power plug
2. Thermostat
3. Heater
240 Volt Plug
Figure 2-9 Carburetor Heaters
2
3
Carburetor Heater for 20 kW Models
GM57968
1. Carburetor heater (air cleaner removed to show heater)
2. Carburetor heater power cord
Figure 2-10 Carburetor Heater for 14 kW Models tp6195
Section 2 Accessories 39
1
Detail view:
2 tt1482b
1. Carburetor heater location under air cleaner. Insert from the back of the generator set.
2. Carburetor heater
Figure 2-11 Carburetor Heater Location on 20 kW
Models
1
2
3 adv-8424
1. 240 VAC carburetor heater power cord
2. 240 VAC connector installed in bulkhead knockout
3. 120VAC receptacle location (for reference)
Figure 2-12 240 Volt Power Connection for
Carburetor Heaters
GM57969-C
40 Section 2 Accessories TP-6803 6/15
2.6 Battery Heater
WARNING
2
1
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the engine heater. Hot parts can cause minor
personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage.
Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.
Optional 120 VAC and 240 VAC battery heater kits are available. The heater is thermostatically controlled.
See Figure 2-13.
Wrap the heater around the battery and secure the cord using cable ties. See Figure 2-14. Plug the power cord into an AC receptacle.
For 120 volt models, plug the carburetor heater into one of the 120 VAC receptacles on the generator set.
240 volt kits use a 3-pin power connector. Generator sets built after 10/9/2013 have a knockout in the bulkhead for the 240 VAC power connector. The 240 volt battery heater kit includes an adapter harness that allows connection of up to three accessories.
Battery Heater Specifications
Heater wrap voltage 100--120 VAC or
200--240 VAC
50/60 Hz
50 Heater wrap rating, Watts
Thermostat temperatures:
On
Off
Battery wrap length, mm (in.)
Power cord length, mm (in.)
18_C (65_F)
27_C (80_F)
711 (28)
1829 (72)
Figure 2-13 Battery Heater Specifications
3
GM92406
Note: Adapter harness for multiple accessories not shown.
1. Battery heater
2. Battery (not included in battery heater kit)
3. Power cord for 240 volt kits
Figure 2-14 Battery Heater
2.7 Emergency Stop Button
An emergency stop button is available as a loose kit.
See the instructions provided with the kit for installation and connection procedures.
Figure 2-15 Optional Emergency Stop Pushbutton
TP-6803 6/15 Section 2 Accessories 41
2.8 OnCue Plus Generator
Management System
The OnCuer Plus Generator Management System allows monitoring and control of your generator set from a personal computer, smart phone, or tablet. OnCue
Plus can also be configured to send email or text message notifications in the event of a generator set fault. Both a network cable connection version (OnCue
Plus) and a wireless version (OnCue Plus Wireless) are available. See TP-6928, OnCue Plus Operation
Manual, for instructions.
OnCue Plus
OnCue Plus is available separately as a loose kit. Use category 5E network cable to connect the RDC2 controller to the customer-supplied Ethernet router or modem. Route the cable with other low-voltage signal wiring (for example, the RBUS communication leads or engine start leads to the transfer switch), in separate conduit from the AC load leads. If the network cable is longer than 100 meters (328 ft.), use a repeater or switch.
Recommended: Use a laptop computer to verify the network connection before connecting to the generator set.
Checking the network connection
1. Check for and turn OFF any wireless connections to the laptop.
2. Connect the network cable to the laptop. Connect the other end of the network cable to the customer’s router or modem.
3. Verify the Internet connection by opening your web browser and going to www.kohlerpower.com or any known website.
4. After verifying the connection through the network cable, disconnect the network cable from the laptop and turn the laptop wireless connections back on.
Connect to the Ethernet cable in the customer connection area of the generator set. See Figure 2-16.
Use an RJ45 inline coupler, provided with the OnCue
Plus kit, to connect the customer’s Ethernet cable to the cable in the customer connection box.
1
GM84094
1. Ethernet cable for optional OnCue Plus connection
Figure 2-16 Network Connection for OnCue Plus
OnCue Plus Wireless
The OnCue Plus Wireless kit allows connection of the generator set to the Internet through the customer’s wireless router without running a network cable from the generator to the customer’s Ethernet router. Follow the instructions provided with the kit to install and set up the wireless kit.
42 Section 2 Accessories TP-6803 6/15
2.9 PowerSync Automatic
Paralleling Module (APM)
The PowerSyncr Automatic Paralleling Module (APM) allows the use of two Model 14RESA or two
20RESA/B/C/D generator sets in a single-phase paralleling system to supply power to one building or site. See Figure 2-17.
The APM provides a common connection point for paralleling generators and permits individual control of the generator connections, allowing for synchronization, redundancy, and generator management.
Generator management provides these features and benefits:
D
Generator management runs one generator set when power requirements are low, and automatically starts, synchronizes, and connects the second generator set when the load increases.
D
Longer generator life: Smart generator management automatically operates the generator with the lowest operating hours first, splitting the run time evenly between the two generator sets and extending the life of both units.
D
Redundancy: If one generator set requires service or even fails, the other generator set is still available to provide power to your critical electronics.
D
Dual fuels: Allows operation of one generator set on natural gas and the other on LPG, if desired.
D
Simultaneous exercise: Setting the exercise time and date on one generator set schedules both generator sets to exercise at the same time.
D
Power during generator service: Customer override allows maintenance or service to one generator set while the other continues to run.
The following combinations of single-phase generator sets can be paralleled:
D
Two single-phase model 14RESA generator sets with the same 110/220, 115/230, 120/240, 220, 230, or 240 volt configuration
D
Two single-phase model 20RESA/B/C/D generator sets with the same 110/220, 115/230, 120/240, 220,
230 or 240 volt configuration
Automatic paralleling requires:
D
D
D
Two single-phase generator sets as shown above
RDC2 paralleling firmware version 105.4 or higher on each generator set.
Download the paralleling firmware from TechTools.
One Model RXT automatic transfer switch (ATS)
D
D
D
One Automatic Paralleling Module (APM) kit
A personal computer (laptop) with Kohlerr
SiteTecht software version 3.5 or higher is required for system setup.
A load management device is required if one generator set cannot support the maximum total load.
The load management device (load shed kit or RXT combined interface/load management board) is necessary in order to shed non-critical loads in the event that one generator set shuts down and the other generator set cannot support all of the loads.
See TT-1596, provided with the APM, for complete installation instructions. The APM and associated equipment must be installed by a Kohlerr trained and authorized distributor or dealer.
If the APM is not installed within sight of the generator sets, local codes may require the installation of circuit breakers near the APM.
Circuit breaker kits are available for installation inside the APM enclosure. See
TT-1596 for the circuit breaker kit numbers for the
14RESA and 20RESA/B/C/D generator sets.
Figure 2-17 PowerSyncr Automatic Paralleling
Module zab26291
TP-6803 6/15 Section 2 Accessories 43
Notes
44 Section 2 Accessories TP-6803 6/15
Section 3 Drawings and Diagrams
Figure 3-1 lists the drawing numbers and page numbers.
Dimension Drawings
14/20RESA/RESAL Dimension Drawing:
Dimensions
Maintenance item locations
Maintenance item locations
Location and clearance requirements, single unit
Location and clearance requirements, parallel units
20RESC/20RESCL Dimension Drawing:
Dimensions
Maintenance item locations
Location and clearance requirements, single unit
Location and clearance requirements, parallel units
Wiring Diagrams
14/20RESA/RESAL Schematic Diagram
1 phase, 2 pole circuit breaker
1 phase, 1 pole circuit breaker
3 phase, 3 pole circuit breaker
14/20RESA/RESAL Wiring Diagram
1 phase, 2 pole circuit breaker
1 phase, 1 pole circuit breaker
3 phase, 3 pole circuit breaker
20RESC/20RESCL Schematic Diagram
1 phase, 2 pole circuit breaker
1 phase, 1 pole circuit breaker
3 phase, 3 pole circuit breaker
20RESC/20RESCL Wiring Diagram
1 phase, 2 pole circuit breaker
1 phase, 1 pole circuit breaker
3 phase, 3 pole circuit breaker
Figure 3-1 Drawings and Diagrams
ADV-8706-C
Sheet 1
Sheet 2
Sheet 3
GM93298-C
Sheet 1
Sheet 2
Sheet 3
ADV-8771
Sheet 1
Sheet 2
Sheet 3
GM96293
Sheet 1
Sheet 2
Sheet 3
Drawing Number
ADV-8424-H
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
ADV-8754
Sheet 1
Sheet 2
Sheet 3
Sheet 4
58
59
60
55
56
57
61
62
63
64
65
66
Page
46
47
48
49
50
51
52
53
54
TP-6803 6/15 Section 3 Drawings and Diagrams 45
Figure 3-2 Dimension Drawing, 14/20RESA/RESAL, ADV-8424, Sheet 1 of 5
46 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-3 Dimension Drawing, 14/20RESA/RESAL, ADV-8424, Sheet 2 of 5
TP-6803 6/15 Section 3 Diagrams and Drawings 47
Figure 3-4 Dimension Drawing, 14/20RESA/RESAL, ADV-8424, Sheet 3 of 5
48 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-5 Dimension Drawing, 14/20RESA/RESAL, ADV-8424, Sheet 4 of 5
TP-6803 6/15 Section 3 Diagrams and Drawings 49
Figure 3-6 Dimension Drawing, 14/20RESA/RESAL, ADV-8424, Sheet 5 of 5
50 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-7 Dimension Drawing, Model 20RESC/20RESCL, ADV-8754, Sheet 1 of 4
TP-6803 6/15 Section 3 Diagrams and Drawings 51
Figure 3-8 Dimension Drawing, Model 20RESC/20RESCL, ADV-8754, Sheet 2 of 4
52 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-9 Dimension Drawing, Model 20RESC/20RESCL, ADV-8754, Sheet 3 of 4
TP-6803 6/15 Section 3 Diagrams and Drawings 53
Figure 3-10 Dimension Drawing, Model 20RESC/20RESCL, ADV-8754, Sheet 4 of 4
54 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-11 Schematic Diagram, 14/20RESA/RESAL, ADV-8706, Sheet 1 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 55
-
Figure 3-12 Schematic Diagram, 14/20RESA/RESAL, ADV-8706, Sheet 2 of 3
56 Section 3 Diagrams and Drawings TP-6803 6/15
-
Figure 3-13 Schematic Diagram, 14/20RESA/RESAL, ADV-8706, Sheet 3 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 57
-
Figure 3-14 Point-to-Point Wiring Diagram, 14/20RESA/RESAL, GM93298, Sheet 1 of 3
58 Section 3 Diagrams and Drawings TP-6803 6/15
-
Figure 3-15 Point-to-Point Wiring Diagram, 14/20RESA/RESAL, GM93298, Sheet 2 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 59
-
Figure 3-16 Point-to-Point Wiring Diagram, 14/20RESA/RESAL, GM93298, Sheet 3 of 3
60 Section 3 Diagrams and Drawings TP-6803 6/15
-
Figure 3-17 Schematic Diagram, Model 20RESC/20RESCL, ADV-8771, Sheet 1 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 61
Figure 3-18 Schematic Diagram, Model 20RESC/20RESCL, ADV-8771, Sheet 2 of 3
62 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-19 Schematic Diagram, Model 20RESC/20RESCL, ADV-8771, Sheet 3 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 63
Figure 3-20 Wiring Diagram, Model 20RESC/20RESCL, GM96293, Sheet 1 of 3
64 Section 3 Diagrams and Drawings TP-6803 6/15
Figure 3-21 Wiring Diagram, Model 20RESC/20RESCL, GM96293, Sheet 2 of 3
TP-6803 6/15 Section 3 Diagrams and Drawings 65
Figure 3-22 Wiring Diagram, Model 20RESC/20RESCL, GM96293, Sheet 3 of 3
66 Section 3 Diagrams and Drawings TP-6803 6/15
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp
ABDC
AC
A/D
ADC adj.
ADV
Ah
AHWT
AISI
ALOP alt.
Al
ANSI aluminum
American National Standards
Institute (formerly American
Standards Association, ASA)
AO
APDC anticipatory only
Air Pollution Control District
API American Petroleum Institute approx.
approximate, approximately
APU
AQMD
AR
AS ampere after bottom dead center alternating current analog to digital advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing amp-hour anticipatory high water temperature
American Iron and Steel
Institute anticipatory low oil pressure alternator
ASE
ASME assy.
ASTM
ATDC
ATS auto.
aux.
avg.
AVR
AWG
AWM bat.
BBDC
BC
Auxiliary Power Unit
Air Quality Management District as required, as requested as supplied, as stated, as suggested
American Society of Engineers
American Society of
Mechanical Engineers assembly
American Society for Testing
Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator
American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator BCA
BCI
BDC
BHP blk.
Battery Council International before dead center brake horsepower black (paint color), block
(engine) blk. htr.
block heater
BMEP bps br.
BTDC brake mean effective pressure bits per second brass before top dead center
Btu British thermal unit
Btu/min.
British thermal units per minute
C cal.
CAN
CARB
CAT5
CB
CC cc
CCA ccw.
CEC cert.
cfh
Celsius, centigrade calorie controller area network
California Air Resources Board
Category 5 (network cable) circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise
Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm
CG
CID
CL cm
CMOS com coml
Coml/Rec Commercial/Recreational conn.
cont.
CPVC crit.
CSA
CT
Cu cUL
CUL cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) communications (port) commercial connection continued chlorinated polyvinyl chloride critical
Canadian Standards
Association current transformer copper
Canadian Underwriter’s
Laboratories
Canadian Underwriter’s
Laboratories cubic inch clockwise city water-cooled cylinder cu. in.
cw.
CWC cyl.
D/A
DAC dB dB(A)
DC
DCR deg., dept.
dia.
DI/EO
DIN
DIP
DPDT
DPST
DS
DVR digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet
Deutsches Institut fur Normung e. V. (also Deutsche Industrie
Normenausschuss) dual inline package double-pole, double-throw double-pole, single-throw disconnect switch digital voltage regulator
E 2 PROM, EEPROM memory
E, emer.
emergency (power source)
ECM electrically-erasable programmable read-only
EDI
EFR e.g.
EG
EGSA electronic control module, engine control module electronic data interchange emergency frequency relay
EIA
EI/EO
EMI emiss.
eng.
EPA
EPS
ER
ES
ESD est.
E-Stop etc.
for example (exempli gratia) electronic governor
Electrical Generating Systems
Association
Electronic Industries
Association end inlet/end outlet electromagnetic interference emission engine
Environmental Protection
Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge estimated emergency stop et cetera (and so forth) exh.
ext.
F
FHM fl. oz.
flex.
freq.
FS ft.
ft. lb.
ft./min.
ftp g ga.
gal.
gen.
genset
GFI exhaust external
Fahrenheit, female flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter hex
Hg
HH
HHC
HP hr.
HS hsg.
HVAC
GND, gov.
gph gpm ground governor gallons per hour gallons per minute gr.
GRD grade, gross equipment ground gr. wt.
gross weight
H x W x D height by width by depth
HC
HCHT
HD
HET hex cap high cylinder head temperature heavy duty high exhaust temp., high engine temp.
hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature HWT
Hz
IBC
IC
ID
IEC
IEEE hertz (cycles per second)
International Building Code integrated circuit inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers
IMS in.
in. H
2 improved motor starting inch in. Hg
O inches of water k
K
J
JIS kA
KB kg in. lb.
Inc.
ind.
int.
int./ext.
internal/external
I/O
IP
ISO inches of mercury inch pounds incorporated industrial internal input/output internet protocol
International Organization for
Standardization joule
Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2 10 bytes) kilogram
TP-6803 6/15 Appendix 67
kg/cm kgm kg/m 3
2 kilograms per square centimeter kilogram-meter kilograms per cubic meter kHz kJ kilohertz kilojoule km kilometer kOhm, k kilo-ohm kPa kph kV kVA kVAR kW kWh kWm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kWth
L kilowatt-thermal liter
LAN local area network
L x W x H length by width by height lb.
lbm/ft 3
LS
L wa
LWL
LWT m
M
LCB
LCD
LED
Lph
Lpm
LOP
LP
LPG pound, pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water level low water temperature meter, milli (1/1000) mega (10 6 when used with SI m m 3 /hr.
m
3 units), male cubic meter
3 cubic meters per hour
/min.
cubic meters per minute mA man.
max.
MB milliampere manual maximum megabyte (2 20 bytes)
MCCB
MCM molded-case circuit breaker one thousand circular mils meggar megohmmeter
MHz mi.
mil min.
misc.
MJ mJ mm megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule millijoule millimeter mOhm, mmilliohm
MOhm, Mmegohm
MOV
MPa mpg mph
MS ms m/sec.
mtg.
MTU
MW mW metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting
Motoren-und Turbinen-Union megawatt
F milliwatt microfarad
N, norm. normal (power source)
NA not available, not applicable nat. gas natural gas
NBS National Bureau of Standards
OV oz.
p., pp.
PC
PCB pF
PF ph.,
PHC
NC
NEC
NEMA
NFPA
Nm
NO
NPSC
NPT normally closed
National Electrical Code
National Electrical
Manufacturers Association
National Fire Protection
Association newton meter normally open no., nos. number, numbers
NPS
NPTF
NR ns
OC
OD
OEM
OF opt.
OS
OSHA
National Pipe, Straight
National Pipe, Straight-coupling
National Standard taper pipe thread per general use
National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed
Occupational Safety and Health
Administration overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase
Phillipsr head Crimptiter
(screw)
Phillipsr hex head (screw) pan head machine (screw) programmable logic control permanent magnet generator potentiometer, potential parts per million psi psig pt.
PTC
PTO
PVC qt.
qty.
R
PHH
PHM
PLC
PMG pot ppm
PROM rad.
RAM
RBUS rms rnd.
RO
ROM rot.
rpm
RS
RTDs programmable read-only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source radiator, radius random access memory
RS-485 proprietary communications
RDO ref.
relay driver output reference rem.
remote
Res/Coml Residential/Commercial
RFI
RH
RHM rly.
radio frequency interference round head round head machine (screw) relay root mean square round read only read only memory rotate, rotating revolutions per minute right side
Resistance Temperature
Detectors
SI/EO sil.
SMTP
SN
SNMP
SPDT
SPST spec specs sq.
sq. cm sq. in.
SMS
SS std.
stl.
tach.
TB
TCP
TD
TDC
TDEC
TDEN
RTU
RTV
RW
SAE scfm
SCR s, sec.
SI
UF
UHF
UIF
UL
UNC
UNF univ.
URL
TDES
TDNE
TDOE
TDON temp.
term.
THD
TIF tol.
turbo.
typ.
VHF
W
WCR w/
WO w/o wt.
xfmr
US
UV
V
VAC
VAR
VDC
VFD
VGA remote terminal unit room temperature vulcanization read/write
Society of Automotive
Engineers standard cubic feet per minute silicon controlled rectifier second
Systeme international d’unites,
International System of Units side in/end out silencer simple mail transfer protocol serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency user interface
Underwriter’s Laboratories, Inc.
unified coarse thread (was NC) unified fine thread (was NF) universal uniform resource locator
(web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer
68 Appendix TP-6803 6/15
Appendix B Electrical Lead Entry Template
Use the full-scale drawing in Figure 1 to mark the openings for the electrical conduit, if desired. Two 13 mm (0.5 inch) holes are also shown for the fuel regulator vent tubes, used only on 20 kW models. See Section 1.9.2 for more information.
SCALE: 1:1
Note: Dimensions are in mm.
Two 13 mm holes are needed for 20 kW models only.
GM78090-B
Figure 1 Template, Drilled or Punched Openings for Regulator Vent Tubes (20 kW only) and Electrical Conduit
TP-6803 6/15 Appendix 69
Notes
70 Appendix TP-6803 6/15
TP-6803 6/15l
E
2011, 2012, 2013, 2014, 2015 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455
For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada:
Call 1-800-544-2444 or visit
KOHLERPower.com

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