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Installation Manual

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4. v 8 noo ama 8 v P10 RBUS Generator Set Terminal Block TB1 See Figure 1 6 for location Check the decal on the generator set for terminal block connections 8 noo uma 8 v P 0 RBUS 5 Old Note See Figure 1 21 for maximum total cable length Leave one end of each cable shield per run 1 run shown disconnected at the last device 1 Communication cable Belden 9402 or equivalent 20 AWG shielded twisted pair cable Figure 1 22 Accessory Module Communication Connection Details TP 6803 12 11 Section 1 Installation 25 Generator Set NOTES e See Figure 1 6 for terminal block location on generator set Check the decal on the generator set for terminal block connections See Figure 1 21 for maximum total cable length per run 3 runs with 1 module each shown See Figure 1 22 for communication connection detail A and B PWR and COM e Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block See Figure 1 24 1 Belden 9402 or equivalent 20 AWG shielded cable with 2 twisted pairs Figure 1 23 Accessory Module Connections three cable runs with one module each tp6809
5. 29 1 8 8 Connect Optional Load Control Module 29 19 1 Batey 2k a eel 90 1 10 Generator Set Accessories sc sms sk ccc ccc ke EEA al EES n Aa 91 1 10 1 Regulator ect 91 1 10 2 Carburetor Heater 00 0 eect teens 32 1 10 3 OnCue Home Generator Management System 33 1 11 Prestart Installation Check 00 ccc cece tenets 34 1 12 Set the Exerciser sms Asks eer Av bei wie dd Ei ee dle ide ed IRK eed 34 1121 RDC2 Controller 0 teen 34 1122 DCZ Controler eh ake E E ni fees SNES 34 1 123 Loaded Exercise i se ssd sis va Saini Sede eta dia jia edad 34 Section 2 Wiring Diagrams Geass uae e bhewe law abe elias 35 Appendix A Abbreviations sosooseessrrrrrrrrrerr etn rr RR RR KK 99 Appendix B Electrical Lead Entry 1 41 TP 6803 12 11 Table of Contents 3 Notes TP 6803 12 11 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 accident
6. Generator Set RBUS Connect all of the shield leads on this end to GROUND at the generato PWR COM PWR COM 12 VDC TO GROUND TB1 Generator Set Terminal Block TB1 See Figure 1 6 for location Check the decal on the generator set for terminal block connections 1 Splice PWR COM 9402 CABLE 9402 CABLE tp6809 Figure 1 24 Multiple Connections to the Generator Set 26 Section 1 Installation TP 6803 12 11 Generator Set NOTES See Figure 1 6 for terminal block location on generator set Check the decal on the generator set for terminal block connections See Figure 1 21 for maximum total cable length with 12 or 14 AWG wire See Figure 1 22 for communication connection A and B PWR and COM detail Connect the cable shield to ground at the generator set 1 Belden 9402 or equivalent 20 AWG shielded cable with 2 twisted pairs Figure 1 25 Accessory Module Connections two cable runs with one and two modules shown TP 6803 12 11 Section 1 Installation 27 Generator Set A and B PWR COM NOTES See Figure 1 6 for terminal block location on generator
7. The National Electrical Code is a registered trademark of the National Fire Protection Association Inc TP 6803 12 11 Section 1 Installation 21 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 and L2 connections on the generator set terminal block 3 Connect the neutral LO and ground GRD leads from the ATS and the main panel to the corresponding connection points on the terminal block See Section 1 8 1 Grounding 4 Connect utility power leads to the terminal block connections labelled Utility Connect to a circuit that is supplied by the utility source and backed up by the generator The power source must be GFCI protected See Section 1 8 4 for more information about the utility power requirement 5 For connection of optional transfer switches the programmable interface module PIM and or a load control module LCM see Section 1 8 5 6 If the OnCue Home Generator Management System will be used with the generator set run category 5E network cable from the generator set to the customer
8. Connect lead 65 to N LP Disconnect Figure 1 14 DSAI Connections Rating 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 e Model Number e kVA e Spec Number e Amps e Serial Number Volts e Fuel original and new e Hz e kw Note LP setup shown 1 LP orifice 2 Hose fitting 3 Regulator 4 Fuel inlet 1 2 in NPT female Figure 1 15 Fuel Regulator and LP Orifice 20RESA RESAL TP 6803 12 11 1 8 Electrical Connections A 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 Hazard
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10. 1 10 1 Regulator Heater The regulator heater kit is designed for Model 2ORESA and 20RESAL 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 1 31 for heater specifications Regulator Heater Heater rating 120 VAC 60 W 4 C 13 C 40 F 55 F Snap action 127 mm 5 in 610 mm 24 in Figure 1 31 Regulator Heater Specifications Thermostat Pad diameter Cord length The regulator heater requires a source of 120 VAC power The generator set is equipped with one 120 VAC receptacle The kit includes an outlet splitter for powering the regulator heater and an_ optional carburetor heater The circuit should be ground fault protected To install the regulator heater kit follow the instructions in TT 1569 provided with the kit Figure 1 32 shows the installed regulator heater kit 1 Regulator heater pad GM79142 2 Regulator mounting screws M933 06035 60 qty 2 re use existing nuts 3 Heater power cord Figure 1 32 Installed Regulator Heater Kit for 2ORESA RESAL Section 1 Installation 31 1 10 2 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C 32 F The carburetor heater prevents condensation and carburetor icing The heater turns on when the temperature at the thermostat fal
11. Installation Residential Commercial Generator Sets Models 14 20RESA 14 20RESAL Controllers NATIONALLY REGISTERED KOHLER POWER SYSTEMS oe California Proposition 65 A 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 Record the product identification information from the generator set nameplate s engine nameplate Model Designation Manufacturer Specification Number Model Designation Serial Number Serial Number Accessory Number Accessory Description 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 0c cece eee eee eee eee RAR RR eens 2 Safety Precautions and Instructions cece cece e eens 5 Introd cti n lian wb elect 9 Startup and Registration 0 cece rr rr ere na 9 Service ASsistance ois sah een cheese eae tea eee oe eee poke ns 10 Section 1 Installation 2 2000 se se e ered nosa asra cece eee eedee cut eeee eee eee RK RAR RER 11 Wd dent
12. Note Do not adjust the fuel metering valves 10 Slide the hose onto the hose fitting and secure it with the clamp 11 Disconnect the DSAI leads for LP The DSAI leads are located near the fuel solenoid valve See Figure 1 11 12 Connect and turn on the new fuel supply TP 6803 12 11 Natural gas setup shown Fuel block Fuel metering valves factory sealed do not adjust Fuel inlet 1 2 in NPT Hose fitting Plug Figure 1 12 Fuel Block 144RESA RESAL 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 LP to Natural Gas To convert from LP vapor 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 13 Fuel DSA Leads 65 and N Connect lead 65 to N Natural Gas LP Disconnect Figure 1 13 DSAI Connection Section 1 Installation 19 1 7 2 Fuel Conversion 20RESA RESAL For LP vapor 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 fu
13. PTC PTO PVC qt qty R rad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers 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 Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million 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 relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rot
14. SANIONFT NOILSNGNOD AYVNOILVLS 30 3SN ANY NOILYTIVISNI JHL 304 SGUVONVLS LE Vd4N 3009 1V901 11 15 3 3430 SI JYNLINYLS V WOUS 32 5 4 434 3 234 JHL 913 SINV1d JAILISNIS FUNLINYAS NAVI OL JONVLSIG AGN 3WNOD3Y 14 8 SINW1d JAILISNIS 53415 ONINIVW3Y 1 9 NI 3 5 3 LV 438 1 89 UL YOOd 391 835 9 v A Las SINVId JAILISNAS JYNLINYNA NAY 30 3 38 53415 3 IV 1 JYNLINYNA NMYT Ol JONVISIG AN3 5 3 IV 038 TJAVYI 1913 yood 391Au3s 7 38 19 815 031 4 220 38 19 8 913 SINIVYLSNOD NOILVTIVISNI YSHLO 404 SYSNMO OL 333438 Ol 138 40 3 15 3 4 1334 8 9 LV JUV OLD 38 8 4 1 5 4 JAILISNIS 6 Vauv 3 89 NI 53181 15 8 2 8310 YO SENYHS SLNV1d ON 8 39 JHL OL 35019 OOL ONIMONS WOY4 5033 8 559 89 1 3 38 OL 431901 39 8 3 9 WOIHL HONI 83 8 6031 L 13 40 3 LSNVHX3 3 1334 01 LSV31 LY 348V S3MVINI YVTINIS ONY J VNYNA 9 G3S019 38 STIVM 32 NO 54000 8 SMOCNIM 5 38 19 815 4 13534340 834084 SVH LAS 7 LAS JHL 40 GNF LSNYHXJ JHL WOYd 1334 S 1SV37 SI 9NINJdO 38 19 815 Y
15. cao 18 JUHM 1HM 07 N3349 NYO Z Qne la yovia L Nid SNOILOSNNOD Sd 1 18 51418 avol ann ASWHd 319 5 5 86 5 3 3 30 303 310 T S 9 Figure 2 3 Point to Point Wiring Diagram GM81217 37 Section 2 Wiring Diagrams TP 6803 12 11 Notes 38 Section 2 Wiring Diagrams TP 6803 12 11 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 cal CAN CARB CAT5 CB CC cc CCA CEC cert cfh 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 aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management Dis
16. em en LYVHO 33S ONINLL LOANNOD LON OG svo d1 OL S9_LOANNOO SVD VANY NI 0001 07ZHO 3dAL 3 4 ONINIL TIIM INOS OM MOO1g TWNINNSL 8 YOLON YaddalS WIS YOLVLS IIS GIONTIOS 5 55 YSLYVLS WS LOSNNOO MIND NODD GuvOd 3 4 3 AVIIY 8 8 YSTIONLNOD 53 948 3 d ILINIVW dN ans X09 YITIONINOD 3 r GNNOYD XO YSTIONLNOD GND INVA TANA Ad ANIONS 4983 35 SYNLVYSdNSL INVIOOO 519 SONVAGY MYVdS WLO IVSA 30010 azv 3 854 3 89448 3 3 8 LINON 82 0 931 68026 oNMWEG NOISIAJE NI IM N 0 89 8 81 3ONVYO 8 N3349 N 99 J N na zz 49 O N ve 6h J N g 1 553 1 8d N 9 UMd ZEL 910 IM uMd St ov ss ri td ss 4 NY9 Stl A ZN dvl 51 14 YMd ona V pne EM WOO WO d ano an9
17. TP 6487 Installation Instructions Load Control Module LCM Installation Instructions Programmable Interface Module PIM TT 1574 TT 1584 Figure 2 Related Literature 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 For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 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 795
18. 7 4 ULL HLL LT LL deed VLU N SS gt Sj n e k r LJ F 7 29 gt GM80110 1 Fuel Regulator 2 Fuel block not shown see Figure 1 12 or LP orifice location see Figure 1 15 Figure 1 11 Fuel System 18 Section 1 Installation Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING h b W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels IGNITION TIMING FUEL TYPE CH980 NATURAL GAS CONNECT 65 N LP_GAS DO NOT CONNECT IGNITION TIMING SEE CHART N3 W2 65 8 4 DSAI Lead Connection 3 Fuel solenoid valve and digital spark advance ignition DSAI leads 4 Fuel inlet 1 2 in NPT female TP 6803 12 11 1 7 1 Fuel Conversion 14RESA RESAL Two fuel connections on the fuel block allow field conversion between natural gas
19. Connect to the Ethernet cable in the customer connection area of the generator set See Figure 1 36 Use an RJ45 inline coupler provided with the OnCue kit to connect the customer s Ethernet cable to the cable in the customer connection box GM84094 1 Ethernet cable for optional OnCue connection Figure 1 36 Network Connection for OnCue Section 1 Installation 33 1 11 Prestart Installation Check 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 e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed Oil Level Maintain the oil level at or near not over the
20. 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 TP 6803 12 11 Appendix B Electrical Lead Entry Template Use the full scale drawing in Figure 3 to mark the openings for the electrical conduit if desired See Section 1 8 2 for more information OZ SCALE FULL Note Dimensions are in mm GM78090 Figure 3 Template Electrical TP 6803 12 11 Appendix 41 Notes 42 Appendix TP 6803 12 11 TP 6803 12 11 2011 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
21. Vapor Gas 203 000 281 000 Btu hr Btu hr y Natural Pipe Gas Length m ft LP Vapor 340 000 Btu hr 193 000 Btu hr Figure 1 9 Fuel Pipe Size Recommendations Fuel Consumption m 3 hr cfh 14RESA RESAL 20RESA RESAL Fuel Type 60 Hz 100 5 4 193 50 Hz 60 Hz 50 Hz 4 9 175 75 47 163 42 148 Natural Gas 50 3 5 124 3 1 108 25 2 6 93 2 4 84 100 2 3 81 2 1 74 75 2 1 75 1 9 68 LP Vapor 50 1 8 60 1 5 53 25 1 2 45 1 1 40 LP vapor conversion factors 8 58 ft 3 1 Ib 0 535 m 1 kg 36 39 ft 3 1 gal Nominal fuel rating Natural gas LP vapor Figure 1 10 Fuel Consumption TP 6803 12 11 37 Md m 1000 Btu ft 3 93 MJ m 2500 Btu ft 3 Section 1 Installation 17 1 7 Fuel Conversion The multi fuel system allows conversion from natural gas to LP vapor or vice versa in the field while maintaining emissions standard compliance A trained technician or an authorized distributor dealer can convert the fuel system Figure 1 11 shows the fuel system components A 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 lls
22. and LP vapor 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 fuel metering adjustments may violate federal or state laws Use the following procedure to convert from natural gas NG to LP vapor The procedure includes moving the fuel connection from the natural gas to the LP port plugging the natural gas port and disconnecting the leads for the digital spark advance ignition DSAI See Figure 1 11 for the fuel system component locations Procedure to convert from NG to LP 14RESA RESAL 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 12 6 Remove the hose fitting from the natural gas outlet port in the fuel block See Figure 1 12 7 Remove the plug from the LP port in the fuel block See Figure 1 12 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
23. be installed and serviced by qualified electrical personnel A 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 A 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 A 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 offthe 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 Safety Precautions and Instructions 7 Welding on the generator set Can cause severe electrical equipment damage Before welding on the gene
24. 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 1 12 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 unloaded and loaded exercise operation 1 12 1 RDC2 Controller When power is applied to the RDC2 controller when the battery or the utility power for the battery charger is 34 Section 1 Installation 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 Date Setting will flash 05Dec2011 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 Figure 1 37 Set Time Date and Exercise RDC2 1 12 2 DC2 Controller To set the exerc
25. mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height 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 106 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 22 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm MQ millionm MOhm MQmegohm MOV MPa mpg mph MS ms nat gas NBS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards 40 Appendix NC NEC NEMA NFPA psi psig pt
26. s router or modem Note Installation of the network cable at the time of generator set installation is highly recommended Installing the Ethernet cable now will make connection much easier if you choose to add OnCue later 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 Ifthe 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 17 The inline coupler is included with the OnCue kit 22 Section 1 Installation GM84094 a Z amp O 1 Ethernet cable for optional OnCue connection 2 AC load connections 3 120VAC utility power connections 4 Low voltage communication and engine start connections 5 Ground connection for communication cable shield Figure 1 17 Electrical Connections 1 8 4 Power Supply 120 VAC 60 Hz power must be supplied to the generator set location for the battery charger integral to the RDC2 and DC2 controllers and the optional accessories shown in Figure 1 18 The power source must be GFCI protected The power to the accessories must be available at all times i e the circuit must be powered by the utility source and backed up by the gener
27. set Check the decal on the generator set for terminal block connections 9 See Figure 1 21 for maximum total cable length with 12 or 14 AWG wire 1 run with 3 modules shown See Figure 1 22 for communication connection A and B detail Connect the cable shield to ground at the generator set 1 Belden 9402 or equivalent 20 AWG shielded cable use one pair or Belden 8723 or equivalent 20 AWG shielded cable 2 12 14 AWG wire tp6809 Figure 1 26 Accessory Module Connections with 12 14 AWG Power Leads one cable run with three modules shown 28 Section 1 Installation TP 6803 12 11 1 8 7 Connect Optional 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 1 Output connections 3 terminal blocks 6 outputs 2 Input connections 2 inputs 3 Rbus communication connection to generator set terminal block TB1 Figure 1 27 Optional PIM The default settings for the inputs and outputs are shown in Figure 1 28 To change the input and output settings use a personal computer running Kohler SiteTech software See TP 6701 SiteTech Software Operation Manual for instructions A personal comput
28. 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 one zaa28533 Figure 1 14 20RESA RESAL Generator Set TP 6803 12 11 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 Part Number OperationManual 14 20RESA RESAL Generator Set TP 6804 Operation Installation Manual Model RXT Automatic Transfer Switch Service Manual 14 20RESA RESAL Generator Set Operation Manual OnCue Software TP 6807 TP 6735 TP 6796 Operation Installation Manual Model RDT Transfer Switch Installation Manual Model RSB Transfer Switch Operation Manual Model RSB Transfer Switch TP 6345 TP 6486
29. 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 LP vapor gas 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 Asuccessful test depends on the ability of the solution to bubble TP 6803 12 11 Hazardous Noise A CAUTION 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 A DANGER Hazardous voltage Will cause severe injury or death This equipment must
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31. 5 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 TP 6803 12 11 1 1 Introduction A DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel Have the generator set installed by an authorized Kohler distributor dealer or authorized representative Install the equipment in compliance 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 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
32. H20 Fuel flow rate maximum Btu hr 14RESA RESAL 20RESA RESAL Natural gas 1000 LP vapor 2500 Figure 1 8 Fuel Supply Verify that the output pressure from the primary gas utility pressure regulator is as shown in Figure 1 8 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 LP tanks verify that the output pressure is as shown in Figure 1 8 See Figure 1 10 for fuel consumption Contact the fuel supplier for flow rate information or a gas meter upgrade The dimension drawing in Section 1 5 shows the location of the fuel inlet connection Use flexible sections to prevent fuel line breakage caused by vibration Hold the fuel solenoid valve with a wrench when tightening the fuel connections Protect all fuel lines from machinery or equipment contact adverse weather conditions and environmental damage 1 6 2 Fuel Pipe Size Ensure that the fuel pipe size and length meet the specifications in Figure 1 9 Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet Add 2 4m 8 ft to the measured length for each 90 degree elbow Compare the total pipe length with the chart in Figure 1 9 to find the required pipe size Contact local LP provider for LP installation information Minimum Gas Pipe Size Recommendation in NPT 14RESA RESAL 20RESA RESAL Natural LP
33. VIINIS YO YOOd LINJA MOGNIM LS3YVAN JHL ZLVOIYONOD 34014 383 5 38 3 10 YO SOILVd 9 38 AW1d LV 6011093814 LON 5 5 3 Z 38 19 815 FHL WONT AVMY GSWIY 31314 09 SI 15 3 I EEE FEK 9 NI 9 NI v 9530415 ININIVWIY TIV NO 11 ONS 15 3 1Y G38 TIAVED ld SINVId JAILISNAS FUN LINAS NAW OL JONVLISIG 030 3 3 134 8 148 AN3 LSAVHX3 LV 438 14 913 53418 ONINIVNIY TIV 3 YOOd 391 835 OL JONVISIG 30 3 3 X000 39 835 A ALON 335 15 31 990 3 19 815 431 4 920 38 19 815 431 4 220 ADV 8424 Sheet 4 ing imension Drawi Figure 1 7 D TP 6803 12 11 Installation 16 Section 1 1 6 Fuel Requirements The generator set operates using natural gas or LP vapor fuel The generator set is EPA certified for both natural gas and LP vapor fuels The fuel system installation must comply with the NEC and local codes 1 6 1 Fuel Supply Because of variable climates and geographical considerations contact the local fuel supplier for fuel system planning and installation Figure 1 8 lists the recommended fuel ratings and other fuel supply information for natural gas and LP vapor fuels Natural Fuel type Gas Fuel supply inlet Fuel supply pressure kPa in
34. ad 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 Figure 1 7 in Section 1 5 Temperature C Exhaust gas exiting the enclosure at rated kW 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 housing to ensure that the air flow is not blocked 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 gt gt REAR VIEW 1 Air intake 2 Exhaust outlet Figure 1 3 Cooling Air Intake and Exhaust 1 5 Dimension Drawings See the dimension drawings in Figure 1 4 through Figure 1 7 for the generator set dimensions fuel and electric inlet locations and recommended clearance TP 6803 12 11 v a v2v8 AQV ue EA on oma Had
35. anagement System The OnCue Home Generator Management System allows monitoring and control of your generator set from a personal computer located in your home or at other remote locations OnCue can also be configured to send email or text message notifications in the event of a generator set fault See TP 6796 OnCue Software Operation Manual for software instructions The OnCue system is available separately as a loose kit Use category 5E network cable to connect the RDC2 controller to the customer supplied Ethernet router and cable or DSL 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 another 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 TP 6803 12 11
36. ate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV SAE scfm SCR 5 sec Sl SI EO sil SMTP SN SNMP SPDT SPST spec specs sq sq cm sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr 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
37. ator Be sure to disconnect power at the distribution panel before making the connections Connect power leads to the utility power connection points on the terminal block See Section 1 8 3 and the wiring diagrams in Section 2 for connection details Power Requirement Max Equipment Watts Amps Volts Battery charger standard integral to RDC2 controller Carburetor heater optional Battery heater optional Fuel regulator heater 20RESA RESAL only Figure 1 18 Power Requirements TP 6803 12 11 1 9 5 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 All connections must comply with applicable state and local codes Note Do not use the Kohler Model RRT transfer switch with the 14 20RESA or 14 20RESAL generator set Communication connections for a Kohler Model RXT transfer switch See Figure 1 19 Use Belden 9402 or equivalent 20 AWG shielded twisted pair cable to connect P10 1 Generator Set through P10 4 on the transfer switch interface module to the generator set terminal block TB1 connections A B PWR and COM See Section 1 8 6 for the maximum cable length Note Connections 3 and 4 on the generator set are not used with the Model RXT transfer switch Engine start connec
38. ble 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 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 30 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 1 5 for the engine starting battery location on the air intake side of the generator set Standard battery cables provide easy connection to the battery EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 1 30 Typical Battery Connection TP 6803 12 11 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 i
39. by 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 A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or dea
40. d 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 ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext IP ISO J JIS k K kA KB KBus kg 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 hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram Appendix 39 kg cm kgm kg m kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW man max MB MCCB MCM meggar MHz
41. e ke nee dene aera E 11 11 1 3 Generator Set Inspection 12 1 4 Location and rr rr rr rr eee 12 1 4 1 Mounting Area 00 0 cette eens 12 1 4 2 Exhaust Requirements 0 0 0 cece rr rss rer rr rr rr ra 12 1 5 Dimension Drawings s sosseerrrrreerereresr rr rr rr rer rr rr rr rr rr rr rr rr 12 1 6 Fuel Requirements 0 000 c cece teen rr resa 17 1 6 1 Fuel gt toa ade beta Mieke red ka a hg ded sin nike 17 16 2 Fuel PIPE SIZE a gmt Po n eh a aaan t 17 1 7 18 1 7 1 Fuel Conversion 4 19 1 7 2 Fuel Conversion 20 1 8 Electrical Connections ueris r denr iori Erpin ra nets 21 1 8 1 Grounding eade 21 1 8 2 Electrical Lead Entry sosse osa dee I sar gr b rs a eee 21 1 8 3 Field Connection Terminal Block sossseesseesseessrss res sees 21 1 8 4 Power Supply 0 due boll ee diet cnet k t B R baren 22 1 8 5 Transfer Switch Connection 0 000 23 18 6 System Connections with Accessory 24 1 8 7 Connect Optional Programmable Interface Module PIM
42. eath 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 A WARNING Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions 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 near
43. ecifications Figure 1 20 Engine Start Connections with Transfer Switch Models RDT or RSB 1 8 6 System Connections with e Use Belden 9402 4 conductor or equivalent 20 Accessory Modules AWG shielded twisted pair cable Note the shield connections shown in Figure 1 22 See Figure 1 22 through Figure 1 26 for connection options with up to three accessory modules Accessory Belden 8723 2 conductor shielded twisted pair modules can include one Model RXT transfer switch cable can be used for connections A and B and one programmable interface module PIM and or one 12 14 AWG wire can be used for the COM and PWR load control module LCM connections The maximum total cable length is the value shown for 12 or 14 AWG wire in Figure 1 21 See Figure 1 21 for the maximum total cable length with 1 2 or 3 accessory modules per cable run Maximum length per run meters ft Number of Modules ATS PIM and LCM per Run Cable TB1 PWR and COM 1 Module 2 Modules 3 Modules Belden 9402 or equivalent 20AWG 61 200 31 100 21 67 14 AWG 152 500 152 500 122 400 12 AWG 152 500 152 500 152 500 Figure 1 21 Total Cable Lengths with Accessory Modules Connected in Series daisy chain 24 Section 1 Installation TP 6803 12 11 Connect one end of each cable shield to GROUND at the generator set Generator Set Connect shields together as shown 5
44. el solenoid valve To convert to LP vapor install the orifice and disconnect the spark advance leads as described below See Figure 1 15 for the fuel system component locations Procedure to Convert from NG to LP 20RESA RESAL 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 15 6 Insert the orifice into the hose fitting See Figure 1 15 7 Slide the hose onto the hose fitting and secure it with the clamp 8 Disconnect digital spark advance module DSAI leads 65 and N5 for LP The DSAI leads are located near the fuel solenoid valve See Figure 1 11 9 Connect and turn on the new fuel supply 10 Reconnect the generator set engine starting battery leads negative lead last 11 Reconnect power to the battery charger 12 Start the generator set by pressing the RUN button on the generator set controller 13 Check for leaks using a gas leak detector 14 Run the generator set and check the operation 15 Press the OFF button to shut down the generator set 20 Section 1 Installation Conversion from LP to Natural Gas To convert from LP vapor to natural gas remove the fuel orifice and connect the DSAI leads together Fu _ BSAl Leads 65 and N Natural Gas
45. er running Kohler OnCue software can be used to actively control PIM outputs See the OnCue Software Operation Manual for instructions PIM Connection Factory Default Setting Input 1 None Input 2 None Output 1 Relay 1 Run Output 2 Relay 2 Output 3 Relay 3 Common Fault Low Battery Voltage Program mable Output 4 Relay 4 Output 5 Relay 5 Output 6 Relay 6 Not in Auto Programmable Cooldown Programmable Normal Source Failure Program mable Figure 1 28 PIM Inputs and Outputs TP 6803 12 11 1 8 8 Connect Optional Load Control Module LCM The optional load control module LCM provides an automatic load management system to comply with Section 702 5 of NEC 2008 Refer to TT 1574 provided with the LCM for installation and connection instructions The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes The load control module automatically manages up to six residential loads Four power relays are provided for management of non essential secondary loads and two relays are available to control two independent air conditioner loads Two kits are available with either a prewired harness for load relay connection or a terminal block The prewired harness requires installation of the LCM within 2 feet of the distribution panel KOHLER POWER SYSTEMS Ga Figure 1 29 Optional Load Contr
46. ery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda toa 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 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 d
47. f 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 12 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 12 Set Exerciser 1 10 Generator Set Accessories Have accessories installed by an authorized distributor dealer or a licensed electrician Follow the installation instructions provided with each kit Use separate conduit for AC and DC leads to reduce the possibility of electrical interference Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local codes See Section 2 Wiring Diagrams for more information regarding generator set electrical connections TP 6803 12 11
48. ipment 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 Hot Parts A 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 TP 6803 12 11 This manual provides installation instructions for Residential Commercial Model 14 20RESA or 14 20RESAL 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 Have an authorized distributor dealer install the generator
49. iser 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 12 3 Loaded Exercise In order to set a loaded exercise using the RDC2 or DC2 controller a Kohler 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 TP 6803 12 11 Section 2 Wiring Diagrams Figure 2 1 lists the wiring diagram numbers and page numbers Wiring Diagram Description Drawing Number Schematic Diagram ADV 8164 36 Point to Point Wiring Diagram GM81217 37 Figure 2 1 Wiring Diagrams and Schematics TP 6803 12 11 Section 2 Wiring Diagrams 35 9 8 mul Er TTT Sad MA OZ V I DILWNSHIS CANIS Y NOINGAN WO NAISSO 30 SIPON TW ROK 00 ETOH NOLSJNNOS NI LEG GSN 38 JON ISAN ONY ALOU 0O AHO 5 ONY NFSSO NI ONIVO SIKL S N POSS IM ATIHON UINOd 0D
50. l Commercial Recreational 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 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 EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay 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 Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt exhaust external Fahrenheit female flat hea
51. lly test and replace the carbon monoxide detectors according to the manufacturer s instructions 1 2 Lifting A 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 Model Weight kg lb 14RESA RESAL 20RESA RESAL Figure 1 1 Approximate Weights 186 410 227 500 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 on the following pages 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 Choose a location that is at least 0 9 m 8 ft from any building or structure and near the incoming gas service Allow a minimum of 2 4 m 8 ft clearance beyond the exhaust end of the generator set Locate the generator set
52. ls below approximately 450 40 F and turns off when the temperature rises above approximately 16 C 60 F The carburetor heaters are shown in Figure 1 33 To install the carburetor heater follow the instructions provided with the kit Figure 1 34 shows the installed carburetor heater kit installed for a 14 kW generator set Figure 1 35 shows the location for the carburetor heater kit on a 20 kW generator set The heater thermostat is installed in the cord Figure 1 33 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 Note Do not place the heater thermostat inside the generator set engine compartment The thermostat must be exposed to the ambient air The heater requires a continuous source of power Plug the carburetor heater into the 120 VAC receptacle provided 14RESA RESAL Carburetor Heater GM19463 2 20RESA RESAL Carburetor Heater GM57968 1 Power plug 2 Thermostat 3 Heater Figure 1 33 Carburetor Heaters 32 Section 1 Installation tp6195 1 Carburetor heater air cleaner removed to show heater 2 Carburetor heater power cord Figure 1 34 14RESA RESAL Carburetor Heater tp6514 1 Carburetor heater location Figure 1 35 20RESA RESAL Carburetor Heater Location on Engine bulkhead removed to show heater location TP 6803 12 11 1 10 3 OnCue Home Generator M
53. n Drawi Figure 1 4 D 13 Installation Section 1 TP 6803 12 11 AIR CLEANER EXHAUST AIR OUTLET OIL DRAIN VALVE METRIC PRO E DIMENSION PRINT ADV 8424 B E PART NO FOR REVISION LEVEL ON REV DATE 10 24 11 NEW D 14 20RESA Figure 1 5 Dimension Drawing ADV 8424 Sheet 2 14 Section 1 Installation TP 6803 12 11 g v NEF anoder 290019 Had 3H LIW 1 68026 9 8 MIN Li v2 01 13431 38 804 UVa 335 SOG 311504 2 NO avd 350 4364 10 LON 193118 NOI1Y907 931178 34 9 5118 9 AYALLVE 13NYd 38 314201 2018 NO I 123 2 YIWOLSND YATIOULNO 1804 8SN 3 188 Lindy YOT AREA AN 5 Figure 1 6 Dimension Drawing ADV 8424 Sheet 3 15 Installation Section 1 TP 6803 12 11 Z v 9 L WEP ene 2 O1 HOG amor 5 P 9 Vims ov wa 0V0 awos T 2 01 H00 LNIdd NOISNSWIG ee an u ON OSL 3A493534 IY NOIINJANI YO N91S30 NOR 09 HY INO HITA NOTLDSNNOD xv
54. n 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 8 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 41 ADV 7876 Note See Appendix B for a full scale template with dimensions 1 1 2 NPT female fuel inlet 2 ATS signal electrical lead entry point 3 Utility voltage electrical lead entry point Figure 1 16 Electrical Lead Entry Locations 1 8 3 Field Connection Terminal Block The generator set is equipped with a field connection terminal block located in the air inlet area near the junction box Leads have been factory installed from the junction box to the terminal block for easy field wiring See the dimension drawing in Section 1 5 for the terminal block location See Figure 1 17 for terminal block details Refer to the terminal block decal for connections and cable sizes Also see Section 2 Wiring Diagrams
55. n 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 A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A 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 batt
56. ol Module LCM shown with optional pre wired harness Section 1 Installation 29 1 9 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A 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 Ib 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
57. ous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to preventthe 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 Code NEC class 1 wire designation and all applicable local codes Canadian installations must comply with the Canadian Electrical Code CEC and applicable local codes 1 8 1 Grounding 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 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 connectio
58. 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 TP 6803 12 11 Section 1 Installation A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 shorttime 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 Periodica
59. rator 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 battery charging alternator connections 5 Attach the weld ground connection close to the weld location 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 A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equ
60. s 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A 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 TP 6803 12 11 Accidental Starting A WARNING FAR 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 o
61. so that the hot exhaust does not blow on plants or other combustible materials Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building 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 12 Section 1 Installation Do not install the 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 atleast 2 4 m 8 ft beyond the exhaust end of the generator set See Figure 1 7 in Section 1 5 1 4 2 Exhaust Requirements Figure 1 2 gives the exhaust temperature at rated lo
62. spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area 30 Section 1 Installation 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 itis charging Do not dispose of a battery ina 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 ca
63. th Carbon monoxide is a poisonous gas presentin 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 e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TP 6803 12 11 Fuel System A WARNING v b W 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
64. tion 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 Connect one end of each cable shield to GROUND at the generator set Interface Board on the Model RXT Transfer Switch Generator Set Terminal Block TB1 See Figure 1 6 for location Check the decal on the generator set for terminal block connections RXT noo al 8 Vv SNAN Old w ID 3 Q O Leave one end of each cable shield disconnected If accessory modules PIM or LCM are connected see Section 1 8 6 Note Generator set terminal block TB1 connections 3 and 4 are NOT USED with the Model RXT ATS 1 Communication cable Belden 9402 or equivalent 20 AWG shielded twisted pair cable Figure 1 19 Model RXT Transfer Switch Communication Connection to Generator Set Terminal Block TP 6803 12 11 Section 1 Installation 23 Generator Set ATS Models RDT or RSB Generator Set Terminal Block TB1 See Figure 1 6 for location Check the decal on the generator set for terminal block connections 1 Engine start leads 3 and 4 See the ATS manual for cable size sp
65. trict 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 Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute 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 TP 6803 12 11 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercia

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