Installation Residential/Commercial Generator Sets Models: 12RESM1 12/17/18RESL 12/17/18RESNT 12/18RESHD Controller: DC-RET Digital Control TP-6516 4/09d
California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Generator Set Identification Numbers Engine Identification Record the product identification numbers from the generator set nameplate(s). Record the product identification information from the engine nameplate.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes 4 TP-6516 4/09
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.
Hazardous Noise CAUTION 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.
Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power.
Introduction This manual provides installation instructions for 12, 17, and 18 kW residential/commercial generator sets equipped with the Kohlerr DC-RET Digital Control. Refer to TP-6517, Operation Manual, for generator set operation and maintenance instructions. 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.
8 Control detail, top view 12 9 11 10 1 2 3 4 5 6 7 See control detail 18 19 20 21 22 26 25 23 17 ADV-7341A-B 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Notes 12 TP-6516 4/09
Section 1 Installation 1.1 General 1.3 Generator Set Inspection 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 Code (NEC) and local code requirements. Do not install this generator set indoors. Complete a thorough inspection of the generator set.
Note: Fuel system may differ from drawing. See Section 1.7.
Figure 1-3 TP-6516 4/09 Generator Set Clearances, 12 kW Models, ADV-7466, Sheet 2 Section 1 Installation 15
Figure 1-4 16 Generator Set Mounting Details and Dimensions, 17/18 kW Models, ADV-7341-B, Sheet 1 Section 1 Installation TP-6516 4/09
Figure 1-5 TP-6516 4/09 Generator Set Clearances, 17/18 kW Models, ADV-7341-B, Sheet 2 Section 1 Installation 17
1.4.1 Exhaust Requirements 3 WARNING Carbon monoxide. Can cause severe fainting, or death. 1 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.
1.6 Fuel Requirements Fuel Consumption at % Rated Load 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.
1.6.2 Fuel Pipe Size 1.7 Fuel Conversion Ensure that the natural gas pipe size and length meet the specifications in Figure 1-13 or Figure 1-14. Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow. Compare the total pipe length with the chart in Figure 1-13 or Figure 1-14 to find the required pipe size.
Procedure to Convert from NG to LP 1. Place the generator set master switch in the OFF position. 6. Place the orifice into the hose fitting. Figure 1-16. See 2 1 2. Disconnect the power to the battery charger. 3 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. 1 tp6514 2 1. LP orifice 3 2. Hose fitting 3.
9. Connect and turn on the new fuel supply. 10. Check that the generator set master switch is in the OFF position. 11. Reconnect the generator set engine starting battery leads, negative (--) lead last. 12. Reconnect power to the battery charger. 13. Start the generator set by moving the generator set master switch to the RUN position. NOTICE Canadian installations only.
1.8.2 1 Remote Start Connection Connect engine start leads from 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. 2 1.8.3 3 12 kW 1 2 ADV-7466 ADV-7341 1. Junction box 2. Field connection terminal block location (see Figure 1-20) 3. Suggested electrical inlet Figure 1-19 Field Wiring Ground the generator set.
1.9 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death.
Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse. Figure 1-22 shows the location of the engine starting battery. Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery. Battery Installation Procedure 1. Ensure that the starting battery is fully charged before placing the battery in service. 2. Clean the battery posts and/or adapters if necessary. 3.
1.10 Carburetor Heater (optional) 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.
1 3 12 kW Carburetor Heater GM19463 1 2 3 GM57968 17/18 kW Carburetor Heater 1. Thermostat 2. Connector 3. Heater Figure 1-26 Carburetor Heaters 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. Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick. Operating Area.
Notes 28 Section 1 Installation TP-6516 4/09
Section 2 Wiring Diagrams Figure 2-1 lists the wiring diagram drawing numbers and drawing references.
- Figure 2-2 30 Schematic Diagram, 12 kW Models, ADV-7351 Section 2 Wiring Diagrams TP-6516 4/09
- Figure 2-3 TP-6516 4/09 Point-to-Point Wiring Diagram, 12 kW Models, GM52471 Section 2 Wiring Diagrams 31
- Figure 2-4 32 Schematic Diagram, Single Phase, 17/18 kW Models, ADV-7353 Section 2 Wiring Diagrams TP-6516 4/09
Figure 2-5 TP-6516 4/09 Point-to-Point Wiring Diagram, Single Phase, 17/18 kW Models, GM52541 Section 2 Wiring Diagrams 33
Notes 34 Section 2 Wiring Diagrams TP-6516 4/09
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. 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 CB cc CCA ccw. CEC cert.
k K kA KB KBus kg kg/cm2 kilo (1000) kelvin kiloampere kilobyte (210 bytes) Kohler communication protocol kilogram kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ 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.
Notes TP-6516 4/09 37
Notes 38 TP-6516 4/09
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com TP-6516 4/09d E 2007, 2008, 2009 by Kohler Co. All rights reserved.