Installation Residential/Commercial Generator Sets Model: 12RES Controller: Advanced Digital Control ADC-RES TP-6967 8/15
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes 4 TP-6967 8/15
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.
Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.
Introduction This manual provides installation instructions for the Model 12RES generator set. Kohler strongly recommends that only factoryauthorized distributors or dealers install and service the generator. Have an authorized distributor/dealer install the generator set outdoors according to the instructions in this manual. The generator set installation must comply with the National Electrical Coder (NEC) and local code requirements. Do not install this generator set indoors.
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.
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-6515, Operation Manual, for additional information.
1.4.2 1.5 Power Supply Air Requirements 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 fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors.
1.7 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 Kohler authorized distributor/dealer can convert the fuel system. Explosive fuel vapors. Can cause severe injury or death. Rating Change Converting the fuel will change the generator set rating. See the generator set specification sheet for ratings with natural gas and LP.
5. Remove the hose clamp and fuel hose from the hose fitting. See Figure 1-10. 6. Use a straight-blade screwdriver to remove the NG orifice from the hose fitting. See Figure 1-11. 7. Insert the LPG orifice into the hose fitting. Use a straight-blade screwdriver to tighten the fitting until it is snug. 8. Slide the hose onto the hose fitting and secure it with the clamp. 9. Disconnect ignition timing leads 65 and N5 for LPG. The ignition timing leads are located near the fuel solenoid valve. See Figure 1-10.
1.8 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. WARNING Have a Kohler authorized distributor/dealer or a licensed electrician make the following electrical connections. The electrical installation must comply with the National Electrical Code (NEC) and all applicable local codes.
1.8.1 Field Connections The generator set is equipped with a field-connection terminal block located below the fuel inlet. Leads have been factory-installed from the junction box to the terminal block for easy field wiring. Refer to the decal near the terminal block for connections. Also see Section 2, Wiring Diagrams. Refer to the decal below the terminal block and the transfer switch specifications for the cable size range for each connection. Route leads through flexible conduit.
1.8.2 Remote Start Connection Connect terminals 3 and 4 to the automatic transfer switch’s engine start terminals or to an optional remote start/stop switch. Route the engine start leads through separate conduit from the AC power and load leads. 1.8.3 WARNING Grounding Ground the generator set. The grounding method must comply with NEC and local codes. Connect the grounding cable to the generator set ground lug, terminal GND inside the controller compartment.
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.
1.10 Accessories Have accessories installed by a Kohler 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.
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 falls below approximately 4_C (40_F) and turns off when the temperature rises above approximately 16_C (60_F). See Figure 1-20. 2 1 The carburetor heater thermostat is installed in the cord.
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.
1.12 Controller Configuration Voltage/frequency setting (Uu). Select the system voltage and frequency from the table in Figure 1-22. 1.12.1 System Parameters Note: The Uu parameter sets the system’s rated voltage and frequency. To adjust the output (measured) voltage and frequency, see Section 1.13, Voltage and Frequency Adjustments. The controller configuration for each generator model is set at the factory and should not normally require changes.
Controller Configuration Mode: Display: Hold the Select button: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the program version number. (The number may be different than the one shown here.) Press the down arrow key and then the up arrow key 3 times to enter the configuration mode. (This is the controller “password.”) . 0 v 1 1 3 Uu 0 1 Now release the Select button.
1.13 Voltage and Frequency Adjustments Changes in voltage and speed adjustments are lost if not saved before the generator set shuts down. The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved. WARNING 1.13.1 Voltage Adjustment Note: Refer to the flowcharts in Figure 1-27 through Figure 1-29 during the following procedure. Hazardous voltage. Moving parts.
8. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the multimeter begins to drop. When the volts/Hz is set correctly, the generator (as load is applied) attempts to maintain normal output until the engine speed drops below the cut-in frequency set in step 7. 9. Reset the engine speed to the operating frequency (50 or 60 Hz) by adjusting the engine governor speed (parameter 4P). 10. Readjust the voltage stability (gain, parameter 2P), if necessary. 11.
Output Voltage and Frequency Adjustment Mode: Display :* Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. x x x x Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number. x. x x Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode. (This is the controller “password.
Continued from Figure 1-27: Display : * Press: To enter engine governor speed coarse adjustment mode. (Parameter 4P) or To raise or lower the engine speed in large increments. To enter engine governor speed fine adjustment mode. (Parameter 4P) or 5 P x x To raise or lower the engine governor stability (gain) in large increments. To enter engine governor stability (gain) fine adjustment mode. (Parameter 5P) or 4 P x x To raise or lower the engine speed in smaller increments.
There are 3 options when the display says SAVE: Press: S AV E To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 1-27. 1 P x x To save changes. Y E S To discard changes without saving. n o or or “Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours. x x x x Now move the master switch to OFF/RESET.
Section 2 Dimension Drawings and Wiring Diagrams Refer to the dimension drawings and wiring diagrams for your model during generator set installation. Figure 2-1 lists the drawing numbers and locations.
Figure 2-2 Dimension Drawing ADV-8024, Sheet 1 32 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 8/15
Figure 2-3 Dimension Drawing ADV-8024, Sheet 2 TP-6967 8/15 Section 2 Dimension Drawings and Wiring Diagrams 33
Figure 2-4 Dimension Drawing, ADV-8024, Sheet 3 34 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 8/15
- Figure 2-5 Schematic Diagram, ADV-7325-E TP-6967 8/15 Section 2 Dimension Drawings and Wiring Diagrams 35
- Figure 2-6 Wiring Diagram, GM51414-E 36 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 8/15
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.
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-6967 8/15 E 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.
