Kohler 12RES Installation Manual
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Kohler 12RES Installation Manual

Kohler 12RES Installation Manual

Residential/commercial generator sets
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Installation
Residential/Commercial Generator Sets
Model:
12RES
Controller:
Advanced Digital Control ADC-RES
TP-6967 2/21a

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Summary of Contents for Kohler 12RES

  • Page 1 Installation Residential/Commercial Generator Sets Model: 12RES Controller: Advanced Digital Control ADC-RES TP-6967 2/21a...

  • Page 2: Product Identification Information

    State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator. Product Identification Information...

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............. Safety Precautions and Instructions .
  • Page 4 Notes TP-6967 2/21...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, WARNING can cause bodily harm and pose life-threatening danger when improperly installed, operated, 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 air cleaner. A sudden Generator set operation. Carbon severe injury or death. Battery gases backfire can cause severe injury or monoxide can cause severe nausea, can cause an explosion. Do not smoke death. Do not operate the generator fainting, or death.
  • Page 7 Fuel System Hazardous Noise WARNING WARNING CAUTION Hazardous voltage. Backfeed to the utility system. cause property damage, Explosive fuel vapors. severe injury, or death. Hazardous noise. Can cause severe injury or death. Can cause hearing loss. If the generator set is used for Use extreme care when handling, standby power, install an automatic Never operate the generator set...
  • Page 8 Connecting the battery and the Hot Parts Notice battery charger. Hazardous voltage will cause severe injury or death. NOTICE WARNING Reconnect battery correctly, Canadian installations only. positive to positive and negative to standby service connect the output of negative, to avoid electrical shock and the generator set to a suitably rated damage to the battery charger and transfer switch in accordance with...

  • Page 9: Introduction

    TP-6196 Information in this publication represents data available Service Manual, Engine 24 690 06 at the time of print. Kohler Co. reserves the right to Parts Catalog TP-5868 change this publication and the products represented Operation Manual, OnCue for ADC...

  • Page 10: Service Assistance

    Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and decals on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.

  • Page 11: Section 1 Installation

    Have the generator set installed by an authorized Kohler Model Weight, kg (lb.) distributor/dealer. For all locations, ensure that the 12RES...

  • Page 12: Generator Set Inspection

    1.3 Generator Set Inspection The generator set is shipped on a plastic mounting pad. Prepare a flat, level mounting area covered with a weed Complete a thorough inspection of the generator set. barrier and gravel or a concrete pad as shown in the Check for the following: generator set clearance drawing.

  • Page 13: Air Requirements

    LPG fuels. Model Inlet Air 26.9 (950) 1.1 (39.2) 28.0 (990) The fuel system installation must comply with applicable 12RES 22.4 (790) 0.9 (32.6) 23.4 (825) national, state, and local codes. Figure 1-4 Air Requirements WARNING Explosive fuel vapors.

  • Page 14: Fuel Supply

    The fuel system. Explosive fuel vapors can cause severe Fuel Consumption, injury or death. Vaporized fuels are highly explosive. Use at % load, m /hr. (cfh) 60 Hz 50 Hz extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment Natural Gas, m /hr.

  • Page 15: Fuel Conversion

    LP. Order a new nameplate with the is gold in color and stamped LPG. The fittings are updated rating and fuel information from a Kohler threaded. A straight-blade screwdriver is required to authorized distributor/dealer, if necessary. Provide the remove and replace the fittings.
  • Page 16 Procedure to Convert from NG to LPG 1. Place the generator set master switch in the OFF/RESET position. 2. Disconnect the utility power to the generator. 3. Disconnect the generator set engine starting battery, negative (- ) lead first. 4. Turn off and disconnect the fuel supply. 5.

  • Page 17: Fuel Conversion, Revised Fuel System

    Conversion from LPG to Natural Gas 1.7.2 Fuel Conversion, Revised Fuel System To convert from LPG to natural gas, repeat the steps above, removing the LPG fuel orifice and installing the The revised fuel system uses a knob that controls a NG fitting.
  • Page 18 Fuel Selection, Revised Fuel System 6. The ignition timing leads 65 and N, located near the regulator. See Figure 1-16. 1. Place the generator set master switch in the OFF/RESET position. a. For natural gas (NG), connect lead 65 to lead N. 2.

  • Page 19: Electrical Connections

    WARNING switch in accordance with Canadian Electrical Code, Part 1. 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 Hazardous voltage.

  • Page 20: Field Connections

    1.8.1 Field Connections 3. See Figure 1-19. Connect the leads from the transfer switch emergency source lugs to the L1 The generator set is equipped with a field-connection and L2 connections on the generator set terminal terminal block located below the fuel inlet. Leads have block.

  • Page 21: Remote Start Connection

    1.8.2 Remote Start Connection 1.9 Battery Connect terminals 3 and 4 to the automatic transfer switch’s engine start terminals or to an optional remote WARNING start/stop switch. Route the engine start leads through separate conduit from the AC power and load leads. 1.8.3 Grounding Ground the generator set.
  • Page 22 Battery gases. Explosion can cause severe injury or connection to the battery. Use the following procedure death. Battery gases can cause an explosion. Do not smoke to install and connect the battery. or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

  • Page 23: Accessories

    Connect customer equipment to terminal strip TB1 on the relay board, following the markings on the board. Have accessories installed by a Kohler authorized Connect to each relay’s normally open or normally distributor/ dealer or a licensed electrician. Follow the closed contacts depending on the application.

  • Page 24: Carburetor Heater

    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).

  • Page 25: Prestart Installation Check

    1.11 Prestart Installation Check Exhaust System. Check for exhaust leaks and blockages. Check the muffler condition. Review the entire installation section. Inspect all wiring Inspect the exhaust system components for cracks, and connections to verify that the generator set is ready leaks, and corrosion.

  • Page 26: Controller Configuration

    Uc05, controller type DC-RET. Changing it frequency to UC01 sets the controller type to ADC-RES. Uc01 is Uu06 115/230 VAC, 50 Hz (single phase) the correct setting for the Model 12RES. Controller type Uc01 ADC-RES (distributor) Communication/Sleep Mode Setting (Cn). (Available (Use for 12RES) on controllers with application code version 1.13 or...
  • Page 27 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 v 1 1 3 number.

  • Page 28: Voltage And Frequency Adjustments

    3. Use the ADC controller to adjust the voltage the output voltage and frequency, if necessary. Have (parameter 1P) until the output voltage reaches the adjustments performed by a Kohler authorized desired value. Refer to the flowcharts in distributor/ dealer.

  • Page 29: Frequency Adjustment

    8. Adjust the volts/Hz (parameter 3P) until the voltage Frequency Adjustment Procedure level measured by the multimeter begins to drop. Note: Refer to the flowcharts in Figure 1-32 through When the volts/Hz is set correctly, the generator Figure 1-34 during the following procedure. (as load is applied) attempts to maintain normal output until the engine speed drops below the 1.
  • Page 30 Output Voltage and Frequency Adjustment Mode: Display :* Move the generator set master switch to the RUN position. The generator set x x x x engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 31 Display : * Continued from Figure 1-32: Press: To enter engine governor speed coarse adjustment mode. (Parameter 4P) To raise or lower the engine speed in large increments. To enter engine governor speed fine adjustment mode. (Parameter 4P) To raise or lower the engine speed in smaller increments.
  • Page 32 There are 3 options when the display says SAVE: S A V E Press: To return to the first parameter, coarse voltage adjustment, to check or change settings before saving. See Figure 1-32. Y E S To save changes. To discard changes without saving. “Yes”or “no”...

  • Page 33: Section 2 Dimension Drawings And Wiring Diagrams

    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. Drawing Description Drawing Number Page Dimension Drawing ADV-9747 Mounting and Dimensions Sheet 1 Clearance Sheet 2...
  • Page 34 Figure 2-2 Dimension Drawing ADV-9747, Sheet 1 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 2/21...
  • Page 35 Figure 2-3 Dimension Drawing ADV-9747, Sheet 2 TP-6967 2/21 Section 2 Dimension Drawings and Wiring Diagrams...
  • Page 36 Figure 2-4 Dimension Drawing, ADV-9747, Sheet 3 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 2/21...
  • Page 37 Figure 2-5 Schematic Diagram, ADV-9232 TP-6967 2/21 Section 2 Dimension Drawings and Wiring Diagrams...
  • Page 38 Figure 2-6 Wiring Diagram, GM115456 Section 2 Dimension Drawings and Wiring Diagrams TP-6967 2/21...

  • Page 39: Appendix A Abbreviations

    (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6967 2/21 Appendix 39...
  • Page 40 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 41 Notes...
  • Page 42 Notes...
  • Page 43 Notes...
  • Page 44 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-6967 2/21a For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com 2015 Kohler Co. All rights reserved.

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