Kohler POWER SYSTEM 12RESM1 Installation Manual
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Kohler POWER SYSTEM 12RESM1 Installation Manual

Residential/commercial generator sets
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Installation
Residential/Commercial Generator Sets
Models:
12RESM1
12RESL
Controller:
DC 2200 Digital Control
TP-6397 4/07c

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Summary of Contents for Kohler POWER SYSTEM 12RESM1

  • Page 1 Installation Residential/Commercial Generator Sets Models: 12RESM1 12RESL Controller: DC 2200 Digital Control TP-6397 4/07c...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Notes TP-6397 4/07...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 6 Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death.
  • Page 7 The fuel system. Explosive fuel Hazardous Voltage/ Grounding electrical equipment. vapors can cause severe injury or Hazardous voltage cause Moving Parts death. Vaporized fuels are highly severe injury or death. Electrocution explosive. Use extreme care when is possible whenever electricity is handling and storing fuels.
  • Page 8 Electrical backfeed to the utility. Hot Parts Notice Hazardous backfeed voltage can cause severe injury or death. Install NOTICE WARNING a transfer switch in standby power Canadian installations only. installations to prevent the connection standby service connect the output of of standby and other sources of power.

  • Page 9: Introduction

    Introduction This manual provides installation instructions for model List of Related Literature 12RESM1 and 12RESL generator sets equipped with Figure 1 identifies related literature available for the the Kohlerr DC 2200 Digital Control. Refer to generator sets covered in this manual. Only trained and TPS-6398, Operation Manual, for generator set qualified personnel should install or service the operating instructions.

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 11: Section 1 Specifications

    Section 1 Specifications 1.1 Specifications 1.2 Components Refer to the generator set specification sheet for engine See Figure 1-1 for generator set component locations. and alternator specifications and generator set application data. See List of Related Materials for the spec sheet part number. ADV-7023-A 1.
  • Page 12 Notes Section 1 Specifications TP-6397 4/07...

  • Page 13: Section 2 Installation

    Section 2 Installation 2.1 General 2.3 Generator Set Inspection Have an authorized distributor/dealer install the Complete a thorough inspection of the generator set. generator set outdoors according to the instructions in Check for the following: this manual. The generator set installation must comply Inspect the generator set for loose or damaged parts with the National Electrical Code (NEC) and local code or wires.
  • Page 14 Figure 2-1 Generator Set Mounting Details and Dimensions, ADV-7023A-D Section 2 Installation TP-6397 4/07...
  • Page 15 Figure 2-2 Generator Set Clearances, ADV-7023B-C TP-6397 4/07 Section 2 Installation...
  • Page 16 Figure 2-3 High Wind Enclosure and Mounting, ADV-7023C-D Section 2 Installation TP-6397 4/07...

  • Page 17: Exhaust Requirements

    2.4.3 Exhaust Requirements WARNING Carbon monoxide. cause severe nausea, fainting, or death. exhaust system must tp6195 1. Exhaust outlet leakproof and routinely inspected. 2. Alternator air intake (both sides) 3. Engine air intake Generator set operation. Carbon monoxide can cause Figure 2-5 Cooling Air Intake and Exhaust severe nausea, fainting, or death.

  • Page 18: Fuel Conversion

    Verify that the output pressure from the primary gas utility (or LP tank) pressure regulator is within the fuel supply pressure range shown in Figure 2-7 and that the utility gas meter flow rate is sufficient to supply the generator set plus all other gas-consuming appliances. Figure 2-7 shows the flow rate required for the generator Figure 2-8...
  • Page 19 Disabling the generator set. Accidental starting can 13. Reconnect power to the battery charger. 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.

  • Page 20: Electrical Connections

    2.6 Electrical Connections NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer WARNING switch in accordance with Canadian Electrical Code, Part 1. Have an authorized distributor/dealer or a licensed electrician make the following electrical connections. Verify that the electrical installation complies with the Hazardous voltage.

  • Page 21: Power Supply

    Cut the leads to the length required and route the leads Kohler generator sets are shipped with the generator to the ATS. Add conduit if required by local codes. Refer neutral attached to the generator in the junction box. At...
  • Page 22 Figure 2-17 shows the location of the engine starting WARNING battery. Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery. Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks.

  • Page 23: Battery Charger

    2.6.5 Battery Charger 2.7 Transfer Switch Connections A 6-amp battery charger is factory-installed in the Connect the engine start leads and power cables from battery compartment. The battery charger’s DC leads the generator wiring kit to the transfer switch. See are factory-connected.

  • Page 24: Carburetor Heater

    2.8 Carburetor Heater The carburetor heater is installed between the carburetor and the air cleaner. See Figure 1-1 for the location. Generator sets are available with or without the carburetor heater. carburetor heater The heater thermostat is installed in the cord. recommended for improved cold starting in locations Figure 2-19 shows the location of the thermostat on the where the ambient temperature drops below 0_C...

  • Page 25: Prestart Installation Check

    Complete the battery manufacturer’s instructions regarding and sign the startup notification form and return copies battery care and maintenance. to Kohler Co. and the distributor/dealer as instructed on Exhaust System. Check for exhaust leaks and the form.
  • Page 26 Notes Section 2 Installation TP-6397 4/07...

  • Page 27: Section 3 Wiring Diagrams

    Section 3 Wiring Diagrams 3.1 Specification Numbers 3.2 Controller Wiring Diagram Reference At the time of print, this manual applied to the model numbers and specification (spec) numbers in Figure 3-1. Figure 3-2 lists the wiring diagram numbers and locations. Model No.
  • Page 28 Figure 3-3 Schematic Diagram, Sheet 1, ADV-7296A- Section 5 Diagrams and Drawings TP-6397 4/07...
  • Page 29 Figure 3-4 Schematic Diagram, Sheet 2, ADV-7296B- TP-6397 4/07 Section 5 Diagrams and Drawings...
  • Page 30 Figure 3-5 Point-to-Point Wiring Diagram, GM49761-A Section 5 Diagrams and Drawings TP-6397 4/07...

  • Page 31: Appendix B Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour engineering special, engineered special ABDC after bottom dead center cubic feet per minute electrostatic discharge alternating current center of gravity est.
  • Page 32 (2 bytes) μF microfarad remote terminal unit KBus Kohler communication protocol N, norm. normal (power source) room temperature vulcanization kilogram not available, not applicable read/write kg/cm kilograms per square nat. gas natural gas...

  • Page 33: Appendix C Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 34: Appendix D General Torque Specifications

    Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Torque Aluminum Grade 2 Grade 5 Grade 8 Size Measurement Grade 2 or 5 8-32 Nm (in. lb.) (16) (20) — 10-24 Nm (in.
  • Page 36 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6397 4/07c 7 Jurong Pier Road Singapore 619159 E 2006, 2007, 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

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Power system 12resl

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