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 Engine Identification Record the product identification numbers from the generator set nameplate(s).
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued Section 3 Drawings and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Appendix B Electrical Lead Entry Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 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 Explosive fuel vapors. Can cause severe injury or death. CAUTION 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.
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.
Introduction 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.
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 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.
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, The exhaust system must be leakproof and routinely inspected. Note: Install carbon monoxide (CO) detector(s) on each level of any building adjacent to a generator set.
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.
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.
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.
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. Apply pipe sealant that is approved for fuel connections.
1.8 Fuel Conversion WARNING 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.
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. 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 3. Disconnect the generator set engine starting battery, negative (--) lead first.
1.8.2 Fuel Conversion, 14RESA/RESAL Equipped with Fuel Orifice Fittings 1 2 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.
10. Connect and turn on the new fuel supply. 15. Run the generator set and check the operation. 11. Reconnect the generator set engine starting battery leads, negative (--) lead last. 16. Press the OFF button to shut down the generator set. 12. Reconnect the utility power to the generator. Conversion from LPG to Natural Gas 13. Start the generator set by pressing the RUN button on the generator set controller.
1.8.3 Fuel Conversion, 20RESA/RESAL/RESC/RESCL LPG setup shown 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. 1 2 3 Note: The generator set harness may contain a pair of ignition timing leads near the fuel solenoid valve.
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 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.
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. 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.
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. 1-Phase, 1-Pole Circuit Breaker Be sure to disconnect power at the distribution panel before making the connections.
1.10 ATS and Accessory Communication Connections 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.
1 Generator Set A B PWR COM 2 ATS (with engine start contacts) 4 3 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.
Maximum length per run, meters (ft.
4 2 3 GND Generator Set RBUS 12 VDC RXT* A A A A B B B B PWR PWR PWR PWR COM COM COM COM 4 3 6 PIM 1 A A B B PWR PWR COM 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. 2. 3. 4. 5. 6. Generator set terminal block. See Figure 1-17 for location.
Generator Set RXT ATS Terminal Block Load Shed Kit 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). PIM D See Figure 1-24 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 1-27.
Generator Set Terminal Block Notes: RXT ATS PIM 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. Load Shed Kit D Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 1-27.
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 Installation Procedure 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. 1. Ensure that the starting battery is fully charged before placing the battery in service.
1.12 Prestart Installation Check WARNING 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 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 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 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.
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 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. Verify that customer-provided equipment complies with applicable local and national electrical codes.
2.4 Regulator Heater 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. 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.
2 1 GM79141C 1. Fuel regulator heater pad 2. Receptacle with adapter (120 VAC kits) Note: See Figure 2-6 for 240 volt power connection.
2.5 Carburetor Heater 1 2 3 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.
1 1 2 3 GM57969-C adv-8424 Detail view: 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 2 tt1482b 1. Carburetor heater location under air cleaner. Insert from the back of the generator set. 2.
2.6 Battery Heater 2 WARNING 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.
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.
2.9 PowerSync Automatic Paralleling Module (APM) Automatic paralleling requires: 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. D RDC2 paralleling firmware version 105.
Notes 44 Section 2 Accessories TP-6803 6/15
Section 3 Drawings and Diagrams Figure 3-1 lists the drawing numbers and page numbers.
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 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.
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.
Notes 70 Appendix TP-6803 6/15
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-6803 6/15l E 2011, 2012, 2013, 2014, 2015 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.
