Installation Residential/Commercial Generator Sets Models: 8/10/12RESV 8/10/12RESVL Controllers: RDC2 DC2 TP-6879 8/14
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. Product Identification Information Generator Set Identification Numbers Engine Identification Record the product identification numbers from the generator set nameplate(s). Record the product identification information from the engine nameplate.
Table of Contents Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Startup and Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 Service Assistance . . . . . . .
Notes 4 TP-6879 8/14
Safety Precautions and Instructions 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.
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.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. 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.
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.
Introduction This manual provides installation instructions for Model 8/10/12RESV or 8/10/12RESVL generator sets. See Figure 1. Refer to TP-6880, 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. Have a Kohlerr authorized distributor/dealer install the generator set outdoors according to the instructions in this manual.
Service Assistance 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 stickers 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.
Section 1 Installation 1.1 Introduction Note: DO NOT install these generator sets inside a building. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. WARNING Carbon monoxide. Can cause severe fainting, or death. nausea, Note: Install carbon monoxide (CO) detector(s) on each level of any building adjacent to a generator set.
1.2 Lifting 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. WARNING 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.
1.4.2 1.5 Dimension Drawings Exhaust Requirements See the dimension drawings in Section 3 for the generator set dimensions, fuel and electric inlet locations, and recommended clearance. WARNING 1.6 Access the Air Intake Area Hot engine and exhaust system. Can cause severe injury or death. 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.
1.7 Fuel Requirements WARNING 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 the NEC and local codes. 1.7.1 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.
Minimum Gas Pipe Size Recommendation, in. NPT 8RESV/RESVL Pipe Length, m (ft.) 10RESV/RESVL 12RESV/RESVL Natural Gas (99,200 Btu/hr.) LPG (160,800 Btu/hr.) Natural Gas (157,100 Btu/hr.) LPG (185,297 Btu/hr.) Natural Gas (208,550 Btu/hr.) LPG (257,000 Btu/hr.) 8 (25) 3/4 3/4 3/4 3/4 3/4 3/4 15 (50) 3/4 3/4 1 3/4 1 3/4 30 (100) 1 3/4 1 1 1 1 46 (150) 1 1 1 1 1 1 61 (200) 1 1 1 1/4 1 1 1/4 1 Figure 1-6 Fuel Pipe Size Recommendations 1.7.
1.8 Fuel Conversion The multi-fuel system allows conversion from natural gas (NG) 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. Use the following procedure to convert the fuel system. The procedure includes removing the side panel, removing the cap from the fuel selector valve, and making the fuel selection. See Figure 1-9 for fuel system components.
6. Remove the cap from the fuel selector valve. See Figure 1-11. Insert a flat head screwdriver under the lip of the cap and push it upwards. Keep the cap close by as it is needed to switch fuels in the next step. 1 2 3 1. Fully left for LPG 2. Fully right for NG 3. Factory-set screw (Do not adjust!) tp6879 Figure 1-13 Valve Positions 8. Replace the cap. 1 9. Connect and turn on the fuel supply (ensure that the fuel supply matches the fuel setting). tp6879 1. Fuel selector cap 10.
1.9 Electrical Connections 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. DANGER 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.
1.9.1 Grounding 1.9.3 Field-Connection Terminal Block Ground the generator set. The grounding method must comply with NEC and local codes. Connect the grounding strap to the generator set ground lug, terminal GND inside the controller compartment. The generator set is equipped with a field-connection terminal block located in the air inlet area inside the junction box. Leads have been factory-installed from the junction box to the terminal block for easy field wiring.
Procedure 1. Drill holes for the conduit fittings. See Figure 1-15 for the recommended electrical inlet locations. Feed the cables through the openings. 7. When connections to the terminal block are complete, replace the cover plate. 2. Connect the leads from the transfer switch emergency source lugs to the L1 and L2 connections on the generator set terminal block. 3.
1.10 ATS and Accessory Connections 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. WARNING Note: Do not use the Kohlerr Model RRT transfer switch with the RESV or RESVL generator set. Hazardous voltage.
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 1-20. Route the engine start leads through separate conduit from the AC power and load leads. 1 Generator Set 2 ATS (with engine start contacts) 3 4 COM PWR B A TB3 tp6803 1. Generator Set Terminal Block. See the dimension drawings in Section 3 for location.
1.10.2 Communication Cable Specifications PWR and COM Connections RBUS Connections A and B For the RBUS communication connections A and B to the Model RXT transfer switch, optional PIM and/or optional LCM or load shed kit, use 20 AWG shielded, twisted-pair communication cable. Belden #9402 (two-pair) or Belden #8762 (single-pair) or equivalent cable is recommended.
1.10.3 System Connections with Accessory Modules programmable interface module (PIM) and/or one load control module (LCM) or load shed kit. See Figure 1-23 through Figure 1-26 for connection options with accessory modules. Accessory modules can include one Model RXT transfer switch, one See Figure 1-21 for the maximum total cable length with 1, 2, or 3 accessory modules per cable run.
2 3 GND Generator Set 3 4 4 12 VDC RBUS COM COM PWR PWR B B A A RXT TB3 1 A A B B PWR PWR COM COM 6 PIM A A B B PWR PWR COM COM 5 LCM or a Load Shed Kit A B Note: See Section 1.10.2, Cable Specifications. PWR COM 1. 2. 3. 4. 5. 6. Generator set terminal block. See Figure 3-4 for location. Check the decal on the generator set for terminal block connections. Connect one end of each cable shield to GROUND at the generator set.
Generator Set RXT ATS TB3 LCM or Load Shed Kit NOTES: D See Figure 3-4 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. D See Figure 1-21 for maximum total cable length per run (3 runs with 1 module each shown). PIM D See Figure 1-23 for communication connection detail (A and B, PWR and COM). tp6803 D Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 1-25.
Generator Set Terminal Block RXT ATS PIM Notes: D See Figure 3-4 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 1-23 for communication connection detail (A and B, PWR and COM). Connect the cable shield to ground at the generator set. LCM or Load Shed Kit D Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 1-25.
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.
1 1.12 Prestart Installation Check 2 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. 1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor. EZ-273000-J Figure 1-27 Typical Battery Connection Prestart Checklist Air Cleaner.
1.13 Set the Exerciser 1.13.2 DC2 Controller 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 unloaded and loaded exercise operation. 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.
1.15 OnCue Plus Generator Management System The OnCuer Plus Generator Management System is included with the 8RESV(L), 10RESV(L), and 12RESV(L) and 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. See G18-247, Quick Start Guide and TP--6928, OnCue Plus Operation Manual, for instructions.
Notes 32 Section 1 Installation TP-6879 8/14
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. 1 2 Use separate conduit for AC and DC leads to reduce the possibility of electrical interference.
2.3 Load Control Module (LCM) The optional Load Control Module (LCM) is available for single-phase generator sets only. The LCM provides 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.
2.4 Load Shed Kit A load shed kit can be used on single-phase systems that include a Model RDT or RXT transfer switch. The load shed kit mounts inside the Model RDT or Model RXT transfer switch enclosure. Figure 3 shows the load shed assembly. The optional load shed kit provides 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.
2.5 Carburetor Heater WARNING 1 3 2 GM57968 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.
Section 3 Drawings and Diagrams Figure 3-1 lists the wiring diagram numbers and page numbers.
Figure 3-2 Dimension Drawing ADV-8539, Sheet 1 38 Section 3 Drawings and Diagrams TP-6879 8/14
Figure 3-3 Dimension Drawing ADV-8539, Sheet 2 TP-6879 8/14 Section 3 Drawings and Diagrams 39
Figure 3-4 Dimension Drawing ADV-8539, Sheet 3 40 Section 3 Drawings and Diagrams TP-6879 8/14
- Figure 3-5 Schematic Diagram, ADV-8552 TP-6879 8/14 Section 3 Drawings and Diagrams 41
- Figure 3-6 Point-to-Point Wiring Diagram, GM89012 42 Section 3 Drawings and Diagrams TP-6879 8/14
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 AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
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 TP-6879 8/14 E 2014 by Kohler Co. All rights reserved. For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call 1-800-544-2444 or visit KOHLERPower.
