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HomeMy WebLinkAbout38314-Z ~ Town of Southold Annex ydFF g 12/10/2013 P.O. Box 1179 54375 Main Road ~1 } p Southold, New York 11971 CERTIFICATE OF OCCUPANCY No: 36651 Date: 12/10/2013 THIS CERTIFIES that the building GENERATOR Location of Property: 1445 Bay Shore Rd, Greenport, SCTM 473889 Sec/Block/Lot: 53.4-4 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this officed dated 9/11/2013 pursuant to which Building Permit No. 38314 dated 9/11/2013 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: accessory generator as applied for. This Certificate of Occupancy replaces COZ-36615 dated 11/21/13, for correction of the application date from 1/1/1900 to 9/11/2013. The certificate is issued to Golden, Annette (OWNER) of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 38314 10/24/13 PLUMBERS CERTIFICATION DATED Authorized Signature TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN CLERK'S OFFICE SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit 38314 Date: 9/11/2013 Permission is hereby granted to: Golden, Annette 1445 Bay Shore Rd Greenport, NY 11944 To: Installation of an accessory generator as applied for per manufacturer's specifications. At premises located at: 1445 Bay Shore Rd SCTM # 473889 Sec/Block/Lot # 51-4-4 Pursuant to application dated 1/1/1900 and approved by the Building Inspector. To expire on 3/13/2015. Fees: ACCESSORY $100.00 CO - ACCESSORY BUILDING $50.00 Total: $150.00 Building Inspector Form No. 6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the Building Department with the following: A. For new building or new use: I. Final survey of property with accurate location of all buildings, property lines, streets. and unusual natural or topographic features. 2. Final Approval from Health Dept. of water supply and sewerage-disposal (S-9 form). 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of 1% lead. 5. Commercial building, industrial building, multiple residences and similar buildings and installations, a certificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. B. For existing buildings (prior to April 9, 1957) non-conforming uses, or buildings and "pre-existing" land uses: 1. Accurate survey of property showing all property lines, streets, building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant. If a Certificate of Occupancy is denied, the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees I. Certificate of Occupancy - New dwelling $50.00, Additions to dwelling $50.00. Alterations to dwelling $50.00, Swimming pool $50.00. Accessory building $50.00. Additions to accessory building $50.00, Businesses $50.00. 2. Certificate of Occupancy on Pre-existing Building - $100.00 3. Copy of Certificate Of Occupancy - $.25 4. Updated Certificate of Occupancy - $50.00 5. Temporary Certificate of Occupancy - Residential $15.00, Commercial $15.00 Date. New Construction: Old or Pre-existing Building: (check one) Location of Property- '~/T~/?!{r~,« Ff.v/'-'c% House No. Street Hamlet Owner or Owncrs of Prop y: 6-:, -42) F ~ Suffolk County Tax Map No 1000, Section 't 7-3 SfY S3 Block Lot Subdivision Filed Ma P' Lot: Permit No. Date of Permit. Applicant: Health Dept. Approval: Underwriters Approval: Planning Board Approval: Request for: temporary Certificate _ Final Certificate: (check one) FCC Submitted: S Applicant Signatt hO~~pF SOUTyolo Town Hall Annex yy Telephone (631) 765-1802 54375 Main Road T 4 Fax(631)765-9502 P.O. Box 1179 043 G roger. riche rt(aDtown.Southold. nY.us Southold, NY 11971-0959 00UNT1,0ct BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICIAL COMPLIANCE SITE LOCATION Issued To: Annette Golden Address: 1445 Bay Shore Rd City: Greenport St: NY Zip: 11944 Building Permit#: 38314 Section: 53 Block: 4 Lot: 4 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE contractor: DBA: A&L Electrical License No: 33933-me SITE DETAILS Office Use Only Residential X Indoor X Basement Service Only Commerical Outdoor X 1st Floor Pool New Renovation 2nd Floor Hot Tub Addition Survey Attic Garage INVENTORY Service 1 ph Heat Duplec Recpt Ceiling Fixtures HID Fixtures Service 3 ph Hot Water GFCI Recpt Wall Fixtures Smoke Detectors Main Panel A/C Condenser Single Recpt Recessed Fixtures CO Detectors Sub Panel A/C Blower Range Recpt Fluorescent Fixture Pumps Transformer Appliances Dryer Recpt Emergency Fixtures Time Clocks Disconnect Switches Twist Lock Exit Fixtures TVSS Other Equipment: 20kw standby generator with 200a transfer switch Notes: Inspector Signature: Date: Oct 24 2013 81-Cert Electrical Compliance Form.xls d0f mg), X TOWN OF SOUTHOLD BUILDING DEPT. 765.1802 INSPECTION [ ] FOUNDATION 1ST [ ] ROUGH PLEIG. [ ] FOUNDATION 2ND [ ] INSULATION [ ] FRAMING / STRAPPING [ ] FINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) ELECTRICAL (FINAL) REMARKS: ~k ~Z ~ - 6K I DATE la 2`~ INSPECTOR DATX ro OC BOUNDA~'IOPt (1ST) W a y FOUNDATION (M) ' z 0 ROUGH FROWO & PLUIVwMG INOM ATION PER N. Y. STATE ENERGY CODE FINAL C? ADDITIONAL COB MENTS • . 70- 77 777 -7- =7 G Q to ?sf r^5 Lie - oCG- °z TOWN OF SOUTHOLD BUILDING PERMIT APPLICATION CHECKLIST BUILDING DEPARTMENT Do you have or need the following, before applying." TOWN HALL Board of Health SOUTHOLD,NY11971 4sets ofBuilding Plans f_y! S TEL: (631) 765-1802 Planning Board approval FAX: (631) 765-9502 Survey SoutholdTown.NorthFork.net PERMIT NO.~ Check )C>O 4-90 Fri Septic Form N.Y.S.D.E.C. Trustees Flood Permit Examined ,20 Storm-Water Assessment Form_ Contact Approved .20 Mail to: Disapprov*adc E3( xpiration _ .'-0__- ( (a 02 TTc/ ef Building Insp t r APPLICATION FOR BUILDING PERMIT Date . 20 INSTRUCT104S a. This application MUST be completely filled in by typewriter o in ink and submitted to the Building Inspector with 4 sets of plans, accurate plot plan to scale. Fee according to schedule. b. Plot plan showing location of lot and of buildings on premises, relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced efore issuance of Building Permit. d. Upon approval of this application, the Building Inspector will ssue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the wort . e. No building shall be occupied or used in whole or in part for at y purpose what so ever until the Building Inspector issues a Certificate of occupancy. f. Every building permit shall expire if the work authorized has nit commenced within 12 months after the date of issuance or has not been completed within 18 months from such date. If o zoning amendments or other regulations affecting the property have been enacted in the interim, the Building Inspector may au horize, in writing, the extension of the permit for an addition six months. Thereafter, a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Departmen for the issuance of a Building Permit pursuant tothc Building Zone Ordinance of the Town of Southold. Suffolk County. New York, and other applicable Laws, Ordinances or Regulations. for the construction of buildings, additions. or alterations or or removal or demolition as herein described. The applicant agrees to comply with all applicable laws, ordinances, building ode, If u hg code, and regulations, an~rto admit authorized inspectors on premises and in building for necessary inspectio is. (Signature of applicant or name, ifacorpomtion) (Mailingaddoes s ofapplicant) Slate whether applicant is owner, lessee, anent, architect, engineer. L.eneral contractor, electrician, plumber or builder L Name of owner of premises A s\) (As on the tax olI or latest deed) If ppli~rati n, sig tore of dul authorized officer I (Name and title of corporate officer) Builders License No. . .j-. xrs License No. Llecirici. ! icense No. Other 1: nse No. I. I. ovation of Im,d on w. !ch proposed work will be done: V- 5- 13 ~Xp,RE R;) Gi2EEny/oe: 55c House Number Street let County Tax Map No. 1000 Section Block Lot Subdivision Filed. - Lot i /State xisting use and occupancy of premises and intended use a d occupancy of proposed construction: a. Existing use and occupancy e~q t v>o-TC-' FFo aeC b. Intended use and occupancy Ck-A)" , ft i Nature o1'work (check which applicable): New Building Addition Alteration Repair Removal Demolition Other Work Z~'V S1 '.1., 'r, Ef 4. Estimated Cost Fee (Description) (To be paid on tiling this application) 5. 1rdwelling, number oPdwelling units Number ofd fling units on each floor If garage, number of cars 6. ll'business, commercial or mixed occupancy. specify nature and lxtent of-each type of use. 7. Dimensions ofexisting structures. if any: Front Rear Depth Height Number of Stories Dimensions of same structure with alterations or additions: ront Rear Depth Height Number of Stories 3. Dimensions of entire new construction: Front Dear Depth Height Number of Stories 9. Size of lot: Front Rear Depth 10. Date of Purchase Name of Former Owner 11. Zone or use district in which premises are situated 12. Does proposed construction violate any zom aw, ordinance or Regulation? YES_ NO 13. Will lot be re-gmdgd?.YES_ NO Vill excess till be remotied fiom premises? YES_NO 14. Names of Owner of premises Address Phone No. Name of Architect Address--~--Phone No Name of Cuntraci6 j .4ddmsss-_~hone No. 15 a. s this property within 100 feet of a tidal wetland or a Imshwaterlwetland? *YES_NO YES. SOUTHOLD TOWN TRUSTEES & D.E.C. PERMITS MAY BE REQUIRED. b. Is this property within 300 feet of a tidal wetland? * YES_ O ` IF YES. D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distandes to property lines. 17. Ifelevation at any point on property is at 10 feet or below, must pr~ vide topographical data on survey. I8 re there any covenants and restrictions with respect to this propeiI y? *YES_ NO * IF YES, PROVIDE A COPY. STATE OF NEW YORK) SS: COU(CY OF, i~) -Ll / A r Y f"/ yj being duly sworn, d~puses and says that (s)he is the applicant (Name of indivon signing contract) above named. (S)Fle is the l (Contractor, Agent. Corporate Officer, etc.) of said owner or owners, and is duly authorized to perform or have performed the said work and to make and file this application: that all statements contained in this application are true to the best of his knomledge and belief, and that the work wilt be performed in the manner set forth in the application filed therew Swo to fore e thi 2 t T f b _ WOO-00, Bop-A"o Notary P blic Signature oSt . Of SO{lr~Q6 Town Hall Annex 41 ? Telephone (631) 765-1802 _ 54375 Main Road H (63t) 7r9505 P.O. Box 1179 G~ • O fOgeGriChe tOWrr.S0 O .nV.US Southold, NY 11971-0959 BUILDING DEPARTMENT Town OF SOUTHOI D APPLICATION FOR ELECTRICAL INSPECTION REQUESTED BY. A-NTltd wi .Tt ~Eo~y-jig Date: Company Name: /f A,L F4CC7RAcAAL c 10 ,vr9196.10'ex 1412-1 . Name: License No.: 3 9 3 3 1 e- Address: jC4A,&vo~ AkCv /6Aet/sa1G A-[.6 N //X36 Phone No.: JOBSITE INFORMATION: (*Indicates required information) *Name: /Q-/V Al U- J rT Cv-o 4 )i-.o *Address: / 54 fLs- i3 A ?//`o,e E *Cross Street: o urn .~.l~ b Cr?~a/ Lv.~ *Phone No.: Permit No.: 3 1 3 I Tax Map District: 1000 Section: Block: Lot: *BRIEF DESCRIPTION OF WORK (Please Print Clearly) ~f /~2CiC7'~a,? D~ GE.t/E/t ~i-77K I I (Please Circle All That Apply) *is job ready for inspection: YES NO Rough In Final *Do you need a Temp Certificate: YES / NO Temp Information (If needed) *Service Size: 1 Phase 3Phase 100 150 200 300 350 400 Other i *New Service: Re-connect Underground Number of Meters Change of Service Overhead Additional Information: PAYMENT DUE WITH APPLICATION 82-Request for inspection Form 1 G ~3 / / r•' Nov 13 OB 10:19a p,pFS s ri a C 0 V f AV6 3 a ' Ada . COT yp 1 ftw awab b . ~ 3'.e • ti. m ,r O comic. ! 7,. ~ v 3e ~o[aYio ' n C'ff• n as 4i 1 r-'- - X01 M1 V3 1 ~ Qt j II r 1 a N. 'yt7P'9Q' M i N 1 R 0,4 Q SURVEY OF PROPERTY AT ARSHAMONAOUE TOWN OF SOUTHOLD SUFFOLK COUNTY N.Y. NOTE, f0p0 - 59 - 04. - ci~ s ra AiffiJOm WIP n' SCALE Y' _ ?0' pF rem eAr ESTATE an AV. OAY IA 1833a ax F7GE A"R 4 M /Me t9W AO1'YAP u0. /Po24 iPnP hrs, ) Oct x ow V~'pp/p~Y9$Od1VU . FARM ZONE A? [ 6R 8 ) Op191U rr PANEL NO. 16~ NF 360613 - 0076 E. App. 14 1993 51~,,f r. mlr oy0'pftn~6 AREA = Y8,6B1 s¢ ft to Ne ry)e t,. CJN70l.Q7 LWES ARE ({EFFREPeGED TO MG MA MW ) N.Y.&. Ltw Pp. 9eRe Ell am A Installation Residential/Commercial Generator Sets Models: 14/20R ESA 14/208 E SAL Controllers: RDC2 D C2 09001 KOHLER® rc:,Tib^l A.IY RF S.S[F SEh POWER SYSTEMS TP_6803 12/11 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 IdentificationInformation 2 Safety Precautions and Instructions 5 Introduction - 9 Startup and Registration 9 Service Assistance 10 Section 1 Installation 11 1,1 Introduction . . 11 1.2 Lifting 11 1.3 Generator Set Inspection 12 1.4 Location and Mounting 12 1.4.1 Mounting Area 12 1.4.2 Exhaust Requirements . 12 1,5 Dimension Drawings...,......._ 12 1.6 Fuel Requirements _ 17 1.61 Fuel Supply 17 1.62 Fuel Pipe Size 17 1.7 Fuel Conversion 18 1.71 Fuel Conversion, 14RESA/RESAL 19 1.7.2 Fuel Conversion, 20RESAIRESAL 20 1.8 Electrical Connections 21 1.8.1 Grounding 21 1.8.2 Electrical Lead Entry 21 1.8.3 Field-Connection Terminal Block 21 1.8.4 Power Supply . . . . . . 22 1 .8.5 Transfer Switch Connection . . 23 1.8.6 System Connections with Accessory Modules , 24 1.8.7 Connect Optional Programmable Interface Module (PIM) 29 1.8.8 Connect Optional Load Control Module (LCM) _ _ 29 1.9 Battery 30 1.10 Generator Set Accessories 31 1.10.1 Regulator Heater 31 1.10.2 Carburetor Heater 32 1.10.3 OnCue Home Generator Management System 33 1.11 Prestart Installation Check 34 112 Set the Exerciser 34 1.12.1 RDC2 Controller 34 1.12.2 DC2 Controller 34 1.12.3 Loaded Exercise 34 Section 2 Wiring Diagrams 35 Appendix A Abbreviations 39 Appendix B Electrical Lead Entry Template 41 TP-6803 12111 Table of Contents 3 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting A WARNING Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, A WARNING 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 eIX Can cause severe injury or death. safely. Read and follow all safety Relays in the battery charger Accidental starting. precautions and instructions. SAVE Can cause severe injury or death. cause arcs or sparks. THESE INSTRUCTIONS. Disconnect the battery cables before Locatethebattery in well-ventilated area. Isolate This manual has several types of safety working on the generator set explosive fumes. the battery chargerfrom precautions and instructions: Danger, Remove the negative lead first e. Warning, Caution, and Notice. when disconnecting the battery. Reconnect the negative lead last Battery electrolyte is a diluted A when reconnecting the battery. sulfuric acid. Battery acid can cause DANGER severe injury or death. Battery acid can cause blindness and burn skin. Danger indicates the presence of a Disabling the generator set. Always wear splashproof safety hazard that will cause severe Accidental starting can cause goggles, rubber gloves, and boots severe injury or death. Before when servicing the battery. Do not personal injury, death, or working on the generator set or open a sealed battery or mutilate the substantial property damage. equipment connected to the set, battery case. If battery acid splashes in disable the generator set as follows: the eyes or on the skin, immediately A WARNING (1) Press the generator set off/reset flush the affected area for 15 minutes button to shut down the generator set. with large quantities of clean water (2) Disconnect the power to the battery Seek immediate medical aid in the case Warning indicates the presence of a charger. if equipped. (3) Remove the of eye contact. Never add acid to a hazard that can cause severe battery cables, negative lead first. battery after placing the battery in personal injury, death, or Reconnect the negative lead last service, as this may result in hazardous substantial property damage. when reconnecting the battery. Follow spattering of battery acid. these precautions to prevent the A starting of the generator set by the Battery acid cleanup. Battery acid CAUTION remote start/stop switch. can cause severe injury or death. Battery acid is electrically conductive Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of hazard that will or can cause minor Battery bicarbonate of soda (baking soda) to a personal Injury or property damage, container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the NOTICE A WARNING neutralizing solution on the spilled battery Notice communicates installation, acid and continue to add the operation, or maintenance information neutralizing solution the spilled that is safety related but not hazard battery acid until all evidence of s related. chemical reaction (foaming) has ceased. Flush the resulting liquid with Safety decals affixed to the equipment water and dry the area. in prominent places alert the operator Sulfuric acid in batteries. or service technician to potential Can cause severe injury or death. hazards and explain how to act safely. The decals are shown throughout this Wear protective goggles and publication to improve operator clothing. Battery acid may cause recognition. Replace missing or blindness and burn skin. damaged decals. TP-6803 12111 Safety Precautions and Instructions 5 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. Carbon monoxide or permit flames or sparks to occur near set with the air cleaner removed. is an odorless, colorless, tasteless, a battery at any time. particularly when nonirritating gas that can cause death if it is charging. Do not dispose of a Servicing the fuel system. A flash inhaled for even a short time. Avoid battery in a fire. To prevent burns and firecan causesevers injury ordeath. breathing exhaust fumeswhen working sparks that could cause an explosion, Do not snake or permit flames or on or near the generator set. Never avoid touching the battery terminals sparks near the carburetor, fuel line, operate the generator set inside a with tools or other metal objects. fuel fitter, fuel pump, or other potential building. Never operate the generator sources of spilled fuels or fuel vapors. etDiscry before servicing elengthe Catch fuels in an approved container set where exhaust gas could seep equipment. Discharge static electricity inside or be drawn into a potentially from your body before touching when removing the fuel line or occupied building through windows, air batteries by first touching a grounded carburetor. intake vents, or other openings. metal surface away from the battery . To Combustible materials. A fire can Carbon monoxide detectors. avoid sparks, do not disturb the battery cause severe injury or death. charger connections while the battery Generator set engine fuels and fuel Carbon monoxide can cause severe nausea, fainting, or death. Install is charging. Always turn the battery vapors are flammable and explosive. carbon monoxide detectors on each charger off before disconnecting the Handle these materials carefully to battery connections. Ventilate the level of any building adjacent to the minimize the risk of fire or explosion. generator set. Locate the detectors to compartments containing batteries to Equip the compartment or nearby area prevent accumulation of explosive with a fully charged fire extinguisher. adequately warn the building's gases. Select a fire extinguisher rated ABC or occupants of the he presence of carbon monoxide. Keep the detectors Battery short circuits. Explosion BC for electrical fires or as operational at all times. Periodically can cause severe Injury or death. recommended by the local fire code or test and replace the carbon monoxide Short circuits can cause bodily injury an authorized agency. Train all detectors according to the and/or equipment damage. personnel on fire extinguisher manufacturer's instructions. Disconnect the battery before operation and fire prevention procedures. Carbon monoxide symptoms. generator set installation or Carbon maintenance. Remove all jewelry monoxide can cause severe before servicing the equipment. Use nausea, fainting, or death. Carbon tools with insulated handles. Remove Exhaust System monoxide is a poisonous gaspresent in the negative lead first when exhaustgases. Carbon monoxide isan disconnecting the battery. Reconnect A WARNING odorless, colorless, tasteless, if the negative lead last when inhaled for nonirritating for eve en o a short short t time. cause death Carbon reconnecting the battery. Never - nhal connect the negative battery cable - monoxide poisoning symptoms include to the positive connection terminal but are not limited to the following: of the starter solenoid. Do not test the • Light-headedness, dizziness battery condition by shorting the • Physical fatigue, weakness in Carbon monoxide. joints and muscles terminals together Can cause severe nausea, a Sleepiness, mental fatigue, fainting, or death, inability to concentrate or speak tomachachetomachache,, ly,blu vomitingng,; nausnausea Engine Backfire/Flash The exhaust system must be • S S leakproof and routinely inspected. Fire If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately A WARNING and remain active. Do not sit, tie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does Fire. not improve within minutes of breathing Can cause severe injury or death. fresh air. Do not smoke or permit flames or sparks near fuels or the fuel system. 6 Safety Precautions and Instructions TP 6803 1271 Fuel System Hazardous Noise WARNING A WARNING A CAUTION ~IN Hazardous voltage. Backfeed to the utility system can cause property damage, severe Explosive fuel vapors. Hazardous noise. injury, or death. Can cause severe injury or death. Can cause hearing loss. If the generator set is used for Use extreme care when handling, Never operate the generator set standby power, install an automatic storing. and using fuels. without a muffler or with a faulty transfer switch to prevent inadvertent exhaust system. interconnection of standby and normal sources of supply. The fuel system. Explosive fuel Engine noise. Hazardous noise can vapors can cause severe injury or cause hearing loss. Generator sets death. Vaporized fuels are highly not equipped with sound enclosures explosive. Use extreme care when CAUTION can produce nose levels greater than A handling and storing fuels. Store fuels 105 dBA. Prolonged exposure to noise 040~ in a q area away from . dBA Wear cause f spark-producing equipment and out of levels greater than 85 permanent hearing ioss Wear hearing the reach of children. Never add fuel to I the tank while the engine is running protection when near an operating because spilled fuel may ignite on generator set. contact with hot arts or from sparks. Welding the generator set. P Can cause severe electrical Do not smoke or permit flames or Hazardous Voltage/ equipment damage. sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines Moving Parts Never weld components of the and connections tight and in good generator set without first condition- Do not replace flexible fuel A DANGER disconnecting the battery, controller lines with rigid lines, Use flexible wiring harness, and engine electronic sections to avoid fuel line breakage control module (ECM). caused byvibration. Donot operate the generator set in the presence of fuel Grounding electrical equipment. leaks, fuel accumulation, or sparks. Hazardous voltage can cause Repair fuel systems before resuming Hazardous voltage, severe injury or death. Electrocution generator set operation. Will cause severe injury or death. is possible whenever electricity is Gas fuel leaks. Explosive fuel present. Ensure you comply with all vapors can cause severe injury or This equipment must be installed and applicable codes and standards. death. Fuel leakage can cause an serviced by qualified electrical Electrically ground the generator set, explosion. Check the LP vapor gas or personnel. transfer switch, and related equipment natural gas fuel system for leakage by antl electrical circuits. Turn off the main using a soap and water solution with circuit breakers of all power sources the fuel system test pressurized to A WARNING before servicing the equipment. Never 6-8 ounces per square inch contact electrical leads or appliances (10-14 inches water column). Do not when standing in water or on wet use a soap solution containing either ground because these conditions ammonia or chlorine because both increase the risk of electrocution. prevent bubbleformation. Asuccessful test depends on the ability of the Hazardous voltage. Moving parts. solution to bubble. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. TP~6803 121l1 Safety Precautions and Insiructions 7 Welding on the generator set. Can Hot Parts Notice cause severe electrical equipment damage. Before welding on the rA NOTICE generator set perform the following WARNING steps: (1) Remove the battery cables, Canadian installations only. For negative lead first. (2) Disconnect standby service connect the output of all engine electronic control module the generator set to a accordance rated (ECM) connectors. (3) Disconnect all ffl transfer switch i accordance with generator set controller and voltage Canadian Electrical Code, Part t. regulator circuit board connectors. Hot engine and exhaust system. (4) Disconnect the engine battery- Can cause severe injury or death. charging alternator connections. Do not work on the generator set until (5) Attach the weld ground connection it cool& close to the weld location. Connecting the battery and the Servicing the exhaust system. Hot battery charger. Hazardous voltage parts can cause severe injury or can cause severe injury or death. death. Do not touch hot engine parts. Reconnect the battery correctly, The engine and exhaust system positive to positive and negative to components become extremely hot negative, to avoid electrical shock and during operation. damage to the battery charger and battery(ies). Have a qualified Servicing the engine heater. Hot electrician install the battery(ies). parts can cause minor personal injury or property damage. Install the Short circuits. Hazardous heater before connecting it to power. voltagelcurrent can cause severe Operating the heater before installation injury or death. Short circuits can can cause burns and component cause bodily injury and/or equipment damage. Disconnect power to the damage. Do not contact electrical heater and allow it to cool before connections with tools or jewelry while servicing the heater or nearby parts. 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 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 8 Safety Precautions and Instructions TP-8803 12111 Introduction This manual provides installation instructions for List of Related Literature Residential/Commercial Model 14/20RESA or 14/20RESAL generator sets. See Figure 1. Refer to Figure 2 identifies related literature available for the TP-6804, Operation Manual, for generator set operation generator sets covered in this manual. Only trained and and maintenance instructions. qualified personnel should install or service the generator set. The generator set is approved for use in stationary applications in locations served by a reliable utility Literature Type Part Number power source. OperationManual, 14/20RESA/RESAL Have an authorized distributor/dealer install the Generator Set TP-6804 generator set outdoors according to the instructions in Operation/Installation Manual, Model this manual. The generator set installation must comply RXT Automatic Transfer Switch TP-6807 with the National Electrical Code (NEC) and local code Service Manual, requirements. Do not install this generator set indoors. 14/20RESAIRESAL Generator Set TP-6735 Information in this publication represents data available Operation Manual, OnCue Software TP-6796 at the time of print. Kohler Co. reserves the right to Operation/Installation Manual, change this publication and the products represented Model ROT Transfer Switch TP-6345 without notice and without any obligation or liability Installation Manual, Model RSB whatsoever. Transfer Switch TP-6486 Read this manual and carefully follow all procedures Operation Manual, Model RSB and safety precautions to ensure proper equipment Transfer Switch TP-6487 operation and to avoid bodily injury. Read and follow the Installation Instructions, Load Control Safety Precautions and instructions section at the Module (LCM) TT-1574 beginning of this manual. Installation Instructions, Programmable Interface Module (PIM) 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 KMN online Warranty Processing System. :T.,znssa Figure 1 14/20RESA/RESAL Generator Set TP-6803 12i 11 9 Service Assistance For professional advice on generator set power China requirements and conscientious service, please contact North China Regional Office, Beijing your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950 • Consult the Yellow Pages under the heading (86) 10 6518 7951 Generators-Electric. (86) 10 6518 7952 Fax: (86) 10 6518 7955 • Visit the Kohler Power Systems website at East China Regional Office, Shanghai KohlerPower.com. Phone: (86) 21 6288 0500 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. Bangalore, India • Call toll free in the US and Canada 1-800-544-2444. Phone: (91) 80 3366208 (91) 80 3366231 • Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972 office. Japan, Korea North Asia Regional Office Headquarters Europe, Middle East, Africa Tokyo, Japan (EMEA) Phone: (813) 3440-4515 Kohler Power Systems Fax: (813) 3440-2727 3 rue de Brennus 93200 Saint Denis Latin America France Latin America Regional Office Phone: (33) 1 49 178300 Lakeland; Florida, USA Fax: (33) 1 49 17830'. Phone: (863) 619-7568 Asia Pacific Fax: (863) 701-7131 Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455 10 TP 6803 12/11 Section 1 Installation 1.1 Introduction A WARNING A DANGER Carbon monoxide. Can cause severe nausea, Hazardous voltage. fainting, or death. Will cause severe injury or death. The exhaust system must be This equipment must be installed and leakproof and routinely inspected. serviced by qualified electrical personnel. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an Have the generator set installed by an authorized Kohler odorless, colorless, tasteless, nonirritating gas that can cause distributor/dealer or authorized representative. Install death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never the equipment in compliance with the National Electrical operate the generator set inside a building. Never operate the Code (NEC) and local codes For Canadian generator set where exhaust gas could seep inside or be installations, refer to the Canadian Electrical Code drawn into a potentially occupied building through windows, air (CEC). intake vents.. or other openings. The generator set must be installed outdoors. The Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon exhaust systems on enclosed units are designed for monoxide detectors on each level of any building adjacent to outdoor installation only the generator set. Locatethe detectors to adequately warn the building's occupants of the presence of carbon monoxide. Note: DO NOT install these generator sets inside a Keep the detectors operational at all times. Periodically test building. and replace the carbon monoxide detectors according to the manufacturer's instructions. 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 1.2 Lifting building's occupants of the presence of carbon monoxide. A WARNING Obtain a building permit and contact your local utility companies to mark the locations of underground pipes and cables. Read and follow the safety precautions in this manual and observe the decals on the equipment. Refer to the Unbalanced weight. diagrams and drawings in this manual for dimensions Improper lifting can cause severe and electrical connections during the installation injury or death and equipment procedure. Read the entire installation procedure and damage. obtain the accessories and tools needed before Do not use lifting eyes. beginning installation. Perform the steps in the order Lift the generator set using lifting bars shown. inserted through the lifting holes on the skid. To install optional accessories, follow the instructions provided with each kit. Model Weight, kg (lb.) I 14RESNRESAL 186 (410) 20RESAfRESAL 227 (500) Figure-1-1 Approximate Weights TP-6803 12,11 Section 1 installation 11 Approximate generator set weights are shown in Do not install the mounting pad directly on grass, wood, Figure 1-1. Use lifting bars inserted through the holes in or other combustible materials, Clear all combustible the skid to lift the unit. See the dimension drawings on materials, including plants and shrubs, building the following pages for lifting hole locations. materials, and lawn furniture, from an area at least 2.4m (8 ft.) beyond the exhaust end of the generator set See 1.3 Generator Set Inspection Figure 1-7 in Section 1.5. Complete a thorough inspection of the generator set. 1.4.2 Exhaust Requirements Check for the following: Figure 1-2 gives the exhaust temperature at rated load. 1. Inspect the generator set for loose or damaged The engine exhaust mixes with the generator set parts or wires. Repair or tighten any loose parts cooling air at the exhaust end of the enclosure. Mount before installation. the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the 2. Check the engine oil. Fill, if necessary, with the clearances shown in Figure 1-7 in Section 1.5. recommended viscosity and grade of oil. Use synthetic oil, API (American Petroleum Institute) Temperature, Service Class SG or higher. See TP-6804, Exhaust -C ('F) Operation Manual, for additional information. Exhaust gas exiting the enclosure at rated kW, `C ("F) 260 (500) 1.4 Location and Mounting Figure 1-2 Exhaust Flow and Temperature Install the generator set outdoors. Choose a location The generator set requires correct air flow for cooling that is at least 0.9 m (3 ft.) from any building or structure and combustion. The inlet and outlet openings in the and near the incoming gas service. Allow a minimum of sound enclosure provide the cooling and combustion 2.4 m (8 ft.) clearance beyond the exhaust end of the air. Figure 1-3 shows the locations of the cooling air generator set. Locate the generator set so that the hot intake and exhaust vents. Inspect the air inlet and outlet exhaust does not blow on plants or other combustible openings inside and outside the housing to ensure that materials. Do not install the generator set where the air flow is not blocked. exhaust gas could accumulate and seep inside or be The generator set is designed to operate with all drawn into a potentially occupied building. enclosure panels and internal baffling in place. If during installation, maintenance or repair the unit must be Notice operated without the complete enclosure and baffling as shipped from the factory make sure the exhaust panel is DO NOT locate the generator set near patios, removed as well. 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. 2 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 ' E e ii ( power outages. Some generator set components become hot when the generator set is running and 733 remain hot for a time after the generator set shuts REAR VIEW down 1 Air intake 2, Exhaust outlet 1.4.1 Mounting Area Figure 1-3 Cooling Air Intake and Exhaust The generator set is shipped on an engineered composite mounting pad. Prepare aflat, level mounting 1.5 Dimension Drawings area covered with a weed barrier and gravel or a concrete mounting pad. Set the composite mounting See the dimension drawings in Figure 1-4 through pad directly on the gravel or concrete. Figure 1-7 for the generator set dimensions, fuel and electric inlet locations. and recommended clearance. 12 Section 1 Installation TP-6803 12111 - - 0 1 1 P _ p -x a xui Px ac. (((~~~x ttx,c n ( _ ~ S~ fill R -A .E'SX +IiY cu' 0:.* t xM gFT?xLyiATSi./ f- [x ~ ~ `F ~ I E ?UE' W MCx t r a PIYFxIid`, r9 `S MF Ix WI'iflflllt r 1 r ILI Y'l 1 , `3 a G m ~ n N 3 y ~ J O I w ~ela$ 03 A ' ~ y? vmnn J Q - as M ~ • ~ - r y y.r a i3 ~ ~~s~~~rkti'~e ar 14 MIN k t st rte' WHLIRCQ 4FfNC Wit' dMEN NWT unaafsn _ ROVb424 O W f? S A J N O Q 0 D 0 A N A ~ x r. (d 'EI yr' m z. . IMMM CQ ~crac D~ WN PLANT _ v, aov~eaza 0 N ~e F, m, . a j ~ I r i ~FII p , . g':", r ~ u v-f. - OG4 GP llx::c X( ( 1 vt. ':RI ~ I t 1 IE R - a SE c le, it ~i IF 4 Al W CE MOP ~i T -4 - { A `ss-~~ a sm Ar 's«x• _ { ( I P e[ YCC !0 tl - IQI4{l + I n u fitl L31 1 A!5E"v AAA 04 FAk -IR !0 x11395:;, 1111111 S PO e! 4 A I AA[ Y 4 i N CLP WAS i:[ P WI,i COYC EA' 1 6E P[ RCS i .M Y 1 O Ix i 1 :LCY[ Oj(Y K I S i- S 5 i[r " W -,."1 A" OF f , •.f W OC•'ii 0"10 J Y= E - T. a S • i .S 9 A: Y4Y] R M03 Ov AJ [ V • SA Clnll~ - W Al, r. - e~ x 1St TF^. [A f M or tN t 3 _ s P2J r r A tev _ \ 11 , tir t L), r(v6v. !l: +UN 1 f[ eery i.OA t Iw (IJ I TS ILI- h S f_: 4 L "C i1 Pr i 1 A {tt3'JIE 45AVC 01, 1 \ ~G!nfG 'Ih rA l.rr .J(tx5 S t S YYJ.' f P' uL_S IL Ft SEIX b ]CY] TIq .AMLS.' t f P i PC. rA3 L 't^!+ ^ S,AFl- M CL A_- !Cb (P•.v. E. A i tx0 OT A[! y. e[r[P iO.pXE85 AV.A JieCG Y. A.. Os .,Bit -1.1 AV G f { FR r0 YP[i[X AtF n ACC X^ air Y:. Sf XI 5E~' r ; it~i- X?l~ ,t..,,;_ :C *11 lw:'' 3 ..GPie1 .P C4 WS EE t Iift - "'-T a LTXj[~y J Y [xt mY4Y+i , t PXFYP( -fR yE T-ttYy' y iFfY rc{w 'a SSS 1y~ 'It J x e ^s`3YAE*s 9a a laiE ~r,Xvi Lx,TtP~,uTyy®x.dYq}A(5 ,ew lot v 9 C ~i a :z8 a~a ~s s V. g '2, Y YN .t µ $4' n,d"t,.y3 Y~,°,'T E_AZPyM, d± 12nE,s av.. P'~ A L ^y wA+'I"2' +#h y`.^ AS TV ~t-zL, 'EA is 's 'tS6A 'rt<lt ' F PA > # f" Y MAIN f~ 1 iU #~'i i [S~g 1.6 Fuel Requirements output pressure is as shown in Figure 1-8. See Figure 1-10 for fuel consumption. Contact the fuel The generator set operates using natural gas or LP supplier for flow rate information or a gas meter vapor fuel. The generator set is EPA-certified for both upgrade. natural gas and LP vapor fuels. The dimension drawing in Section '.5 shows the The fuel system installation must comply with the NEC location of the fuel inlet connection. Use flexible and local codes. sections to prevent fuel line breakage caused by vibration. Hold the fuel solenoid valve with a wrench 1.6.1 FUQI Supply when tightening the fuel connections. Protect all fuel lines from machinery or equipment contact, adverse Because of variable climates and geographical weather conditions, and environmental damage. considerations, contact the local fuel supplier for fuel system planning and installation. Figure 1-8 lists the 1.6.2 Fuel Pipe Size recommended fuel ratings and other fuel supply information for natural gas and LP vapor fuels. Ensure that the fuel pipe size and length meet the specifications in Figure 1-9. Measure the pipe length Natural LP from the primary gas pressure regulator to the pipe Fuel type Gas Vapor connection on the generator set fuel inlet. Add 2.4 m Fuel supply inlet 1/2 NPT (8 ft.) to the measured length for each 90 degree elbow. Fuel supply pressure: 1.3-27 17-2.7 Compare the total pipe length with the chart in kPa (in. H2O) (5-11) (7-11) Figure 1-9 to find the required pipe size. Fuel flow rate, maximum, Btu/hr Contact local LP provider for LP installation information. 14RESAIRESAL 193,000 203,000 20RESAIRESAL 281,000 3401000 Minimum Gas Pipe Size Recommendation, in. NPT Nominal Fuel Rating, BtU(ft 3 14RESA/RESAL 20RESA/RESAL Natural Natural Natural gas 1000 Pipe Gas LP Vapor Gas LP Vapor Length, (193.000 (203.000 (281.000 (340.000 LP vapor 2500 in (1t-) Btu/hr) Btu/hr) Btulhr.) Btujhr.) Figure 1-8 Fuel Supply e (25) 314 314 1 3/4 15 (50) 1 3/4 1 1 Verify that the output pressure from the primary gas 30 (100) 1 1 1 1/4 1 utility pressure regulator is as shown in Figure 1-8 and 46 (150) 1 114 1 1 1/4 1 114 that the utility gas meter flow rate is sufficient to supply the generator set at rated load plus all other 61 (200) 11/4 1 11/4 1114 gas-consuming appliances. For LP tanks, verity that the Figure 1-9 Fuel Pipe Size Recommendations Fuel Consumption, m3/hr. (cfh) ,I 14RESA/RESAL.. 20RESA/RESAL Fuel Type % Load 60 Hz 50 Hz 60 Hz 60 Hz 100% 5.4 (193) 4.9 (175) 8.0 (281) 6.4 (225) 75% 4.7 (163) 4.2 (148) 6.9 (243) 5.4 (189) Natural Gas 50% 3.5 (124) 3.1 (108) 46 (161) 3.9 (139) 25% 2.6 (93) 24 (84) 3.6 (127) 29 (103) 100-A 2.3 (81) 21 (74) 3.9 (136) 2.9 (102) 75% 2.1 (75) 1.9 (68) 3.1 (109) 2.4 (85) LP Vapor 50% 1.8 (60) 1,5 (53) 2.3 (82) 1.8 (63) 25% 1.2 (45) 1.1 (40) 1.7 (59) 1.3 (47) LP vapor conversion factors: Nominal fuel rating: 8.58 ft.3 = 1 a Natural gas. 37 MJ/m3 (1000 Bta/8,3) 0.535 m3 = 1 kg LP vapor. 93 MJ/m3 (2500 BtuM 3) 36.39 k3 = 1 gal. Figure 1-10 Fuel Consumption TP-6803 12,111 Section l Installation 17 1.7 Fuel Conversion Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the The multi-fuel system allows conversion from natural generator set or connected equipment, disable the generator or vice-versa) in the field while setasfollows! (1) Move the generator set master switch to the gas to LP vapor (or first negative the (ba-) lead first emissions-standard compliance. Atrain (ed 3) Remove . the e battery cabl batter able es, power (3) Rem lead technician or an authorized distributor/dealer can Reconnect the negative lead last when reconnecting the convert the fuel system. battery Follow these precautions to prevent starring of the generator set by an automatic transfer switch, remote Figure 1-11 shows the fuel system components. start/stop switch, or engine start command from a remote computer. A WARNING A WARNING all ~I` 41R, Accidental starting. Can cause severe injury or death. Explosive fuel vapors. Disconnect the battery cables before Can cause severe injury or death. working on the generator set. Use extreme care when handling, Remove the negative lead first storing, and using fuels. when disconnecting the battery. Reconnect the negative lead last when reconnecting the battery. 'j 2 ilF 1 `{i 3 l~ 4 DSAI Lead Connection GMtlUn6 1. Fuel Regulator 3. Fuel solenoid valve and digital spark advance ignition (DSAI) 2. Fuel block (not shown see Figure 1-12) or LP orifice location leads (see Figure 145) 4. Fuel inlet, 1/2 in. NPT female Figure 1-11 Fuel System 18 Section 1 Installation TP-6803 12(11 1.7.1 Fuel Conversion, 14RESA/RESAL 1 Two fuel connections on the fuel block allow field- 5 conversion between natural gas and LP vapor. The fuel z, metering valves are factory-set and sealed to comply Natural gas with applicable emission standards and to provide the 4 setup shown 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, 3 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. \ cues 1. Fuel Mock Procedure to convert from NG to LP, 2. Fuel metering valves-factory-sealed, do riot adjust 14RESA/RESAL 3. Fuel inlet, 112 in. NPT 4. Hose fitting 1. Press the OFF button on the generator set s' Plug controller. Figure 1-12 Fuel Block. 14RESAIRESAL 2. Disconnect the power to the battery charger. 13. Reconnect the generator set engine starting battery leads, negative lead last. 3. Disconnect the generator set engine starting battery, negative lead first. 14 Reconnect power to the battery charger. 4. Turn off the fuel supply 15. Start the generator set by pressing the RUN button 5. Remove the hose clamp and fuel hose from the on the generator set controller. hose fitting in the fuel block. See Figure 1-12. 16. Check for leaks using a gas leak detector. 6. Remove the hose fitting from the natural gas outlet 17 Run the generator set and check the operation. port in the fuel block. See Figure 1-12. 16. Pressthe OFF button toto shutdown thegenerator 7. Remove the plug from the LP port in the fuel block. set. See Figure 1-12. 6. Clean the plug with a dry cloth or brush, apply fresh Conversion from LP to Natural Gas pipe sealant, and install the plug into the natural To convert from LP vapor to natural gas, follow the fuel gas outlet port. conversion procedure above, moving the hose fitting to 9. Clean the hose fitting with a dry cloth or brush, the natural gas port and plugging the LP port. Connect apply fresh pipe sealant to the threads: and install the DSAI leads for natural gas. See Figure 7 -13. the fitting into the LP port. Fuel DSAI Leads 65 and N Note: Do not adjust the fuel metering valves. Natural Gas Connect lead 65 to N LP Disconnect 1 D. Slide the hose onto the hose fitting and secure it with the clamp Figure 1.13 DSAI Connection . 11. Disconnect the DSAl 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 Section 1 Installation 19 1.7.2 Fuel Conversion, 20RESA/RESAL Conversion from LP to Natural Gas For LP vapor fuel: an orifice is used in the fuel line. The To convertfrom LP vapor to natural gas, remove the fuel unit is typically shipped set up for natural gas, with the orifice and connect the DSAI leads together. loose orifice tied near the fuel solenoid valve. To convert to LP vapor, install the orifice and disconnect the spark Fuel DSAI Leads 65 and N advance leads as described below. See Figure 1-15 for Natural Gas Connect lead 65 to N the fuel system component locations. LP Disconnect Procedure to Convert from NG to LP, Figure 1-14 DSAI Connections 20RESA/RESAL Rating 1. Press the OFF button on the generator set controller. Converting the fuel will change the generator set rating. See the generator set specification sheet for ratings with 2. Disconnect the power to the battery charger, natural gas and LP. Order a new nameplate with the updated rating and fuel information from an authorized 3. Disconnect the generator set engine starting distributor/dealer, if necessary. Provide the following battery, negative lead first. information from the original nameplate: 4. Turn off the fuel supply. • Model Number • kVA • Spec Number • Amps 5. Remove the hose clamp and fuel hose from the • Serial Number • Volts hose fitting. See Figure 1-15. • Fuel (original and new) • Hz • kw 6. Insert the orifice into the hose fitting. See Figure 1-15. Note: LP setup 7. Slide the hose onto the hose fitting and secure it shown with the clamp. ' 8. Disconnect digital spark-advance module (DSAI) rss.~ r; leads 65 and N5 for LP. The DSAI leads are located 2 1 near the fuel solenoid valve. See Figure 1-11. yLr 3 9. Connect and turn on the new fuel supply. "s; 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. 4 14. Run the generator set and check the operation. 1- LP orifice GMM143 2. Hose fitting 15. Press the OFF button to shut down the generator 3. Regulator 4. Fuel inlet, 112 in. NPT female set. Figure 1-15 Fuel Regulator and LP Orifice. 20RESA/RESAL 20 Section 1 Installation TP6803 12111 1.8 Electrical Connections generator set will operate properly with the neutral either bonded to ground or isolated from ground at the g DANGER 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 Hazardous voltage. Section 250 is one example that has a very good Will cause severe injury or death. explanation of the neutral grounding requirements for This equipment must be installed and generators. serviced by qualified electrical personnel. 1.8.2 Electrical Lead Entry Grounding electrical equipment- Hazardous voltage can Drill or punch holes in the enclosure for the electrical cause severe injury or death. Electrocution is possible conduit in the locations shown in Figure 1-16. A whenever electricity is present. Ensure you comply with all full-scale dimensioned template for the hole locations is applicable codes and standards. Electrically ground the printed in Appendix B. See page 41, generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Nevercontad - - 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. Hazardous backfeed voltage can cause severe injury or death. Install a transfer j switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed intoa utility electrical systemcan cause severe injuryordeath 1 ,y j 2 to utility personnel working on power lines. 9 NOTICE L1 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 Auv-Ye]e electrician make the following electrical connections. Note: See The electrical installation must comply with the National Appendix B for a full-scale template Electrical Code (NEC) class 1 wire designation and all with dimensions. applicable local codes. Canadian installations must 1. 1/2 NPT female fuel inlet comply with the Canadian Electrical Code (CEC) and 2. ATS signal electrical lead entry point applicable local codes. 3. Utility voltage electrical lead entry point 1.8.1 Grounding Figure 1-16 Electrical Lead Entry Locations Ground the generator set. The grounding method must 1.8.3 Field-Connection Terminal Block comply with NEC and local codes. Connect the grounding strap to the generator set ground lug, The generator set is equipped with a field-connection terminal GND inside the controller compartment. terminal block located in the air inlet area near the junction box. Leads have been factory-installed from Generator sets are shipped with the generator neutral the junction box to the terminal block for easy field bonded (connected) to the generator ground in the wiring, junction box. The requirement for having a bonded (grounded) neutral or ungrounded neutral is determined See the dimension drawing in Section 1.5 for the by the type of installation. At installation, the neutral can terminal block location. See Figure 1-17 for terminal be grounded at the generator set or lifted from the block details. Refer to the terminal block decal for ground stud and isolated if the installation requires an connections and cable sizes. Also see Section 2, Wiring ungrounded neutral connection at the generator. The Diagrams. 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 5 low-voltage communication leads through separate 2 conduit. 4 3 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 Ll and L2 connections on the generator set terminal block. GM81091 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. 1. Ethernet cable for optional OnCue connection 4. Connect utility power leads to the terminal block 2. load connections 3. 12 0VAC utility power connections connections labelled Utility. Connect to a circuit 4. Low voltage communication and engine start connections that is supplied by the utility source and backed up 5 Ground connection for cornnumication cable shield. by the generator. The power source must be GFCI protected. See Section 1.8.4 for more information Figure 1-17 Electrical Connections about the utility power requirement 7.8.4 Power Supply 5. For connection of optional transfer switches. the programmable interface module (PIM), and/or a 120 VAC, 60 Hz power must be supplied to the load control module (LCM), see Section 1.8.5. generator set location for the batterycharger (integral to the RDC2 and DC2 controllers) and the optional 6. If the OnCue Home Generator Management accessories shown in Figure 1-18. The power source System will be used with the generator set, run must be GFCI protected. The power to the accessories category 5E network cable from the generator set must be available at all times, i.e. the circuit must be to the customer's router or modem. powered by the utility source and backed up by the Note: Installation of the network cable at the time generator. of generator set installation is highly Be sure to disconnect power at the distribution panel recommended. Installing the Ethernet cable before making the connections. Connect power leads to now will make connection much easier if you the utility power connection points on the terminal block. choose to add OnCue later. See Section 1.8.3 and the wiring diagrams in Section 2 a. Route the network cable with other low-voltage for connection details. signal wiring (for example, the RBUS Power Requirement, Max. communication leads or engine start leads to the transfer switch), in separate conduit from Equipment Watts Amps Volts the AC load leads. If the network cable is longer Battery charger (standard, than 100 meters (328 ft.), use a repeater or integral to RDC2 controller) 120 1 120 switch. Carburetor heater (optional) 37 0.33 b. Use an RJ45 inline coupler to connect the Battery heater (optional) 110 0.92 120 Ethernet cable to the cable in the customer Fuel regulator heater 60 0,50 120 connection box. See Figure 1-17. The inline (20RESAiRESAL only) coupler is included with the OnCue kit. Figure 1.18 Power Requirements 22 Section 1 Installation TP-6803 12111 1.8.5 Transfer Switch Connection through Pl0-4 on the transfer switch interface module to the generator set terminal block TB1 connections A. B, Connect the ATS or remote start/stop switch. Connect PWR, and COM. the load leads from the generator set to the Emergency source lugs on the ATS Route low-voltage See Section 1.8.6 for the maximum cable length communication leads through separate conduit. All connections must comply with applicable state and local Note: Connections 3 and 4 on the generator set are not codes. used with the Model RXT transfer switch. Note: Do not use the Kohler Model RRT transfer Engine start connection for other transfer switch with the 14/20RESA or 14/20RESAL switches or a remote start/stop switch: generator set. Connect the engine start leads from the transfer switch Communication connections for a Kohler or remote start switch to terminals 3 and 4 on the Model RXT transfer switch: terminal block. See Figure 1-20. Route the engine start leads through separate conduit from the AC power and See Figure 1-19. Use Belden #9402 or equivalent load leads. 20AWG shielded, twisted-pair cable to connect P10-1 - - - Connect one end of each cable shield to Generator Set GROUND at the generator set. GNO I i • n A n - it B RBUS rvrn 1 Interface Board on the PW Model RXT Transfer Switch 12 VDC COMA- MM 4 A RXT 3 1 n in r T81 _i n I t n-~ vii Generator Set Terminal Block TB1. Leave one end of each cable shield disconnected. See Figure 1.6 for location. Check the If accessory modules (PIM or LCM) are connected, decal on the generator set for terminal block see Section 1.8.6. connections. 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 l installation 23 Generator Set T81: A B Pw ATS cG Models RDT 4 i or RSB 3.. _~..j Generator Set Terminal Block TB1. See Figure 1-6 for location Check the decal an the generator set for terminal block corrections. ts,easa 1. Engine start leads 3 and 4. See the ATS manual for cable size specifications. Figure 1-20 Engine Start Connections with Transfer Switch Models RDT or RSB 1.8.6 System Connections with • 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 #12-14AWGwirecan beusedfortheCOM andPWR 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 (rB1-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 (5DD) 152 (500) Figure 1-21 Total Cable Lengths with Accessory Modules Connected in Series (daisy-chain) 24 Section 1 Installation TP-6803 12111 Connect one end of each cable shield - - to GROUND at the generator set. GND I Generator Set • n RBUS A A Conned shields together B a . l) r_.- as shown. 12 VDC caM .1 / RXT+---...\ 4 ~~rr ddd / /ss TB1 A..... r - R WNR coM ` 2 =m E ~r~c <ess; Generator Set Terminal Block TB1. `-----f- See Figure 1-6 for location. Check the - - - decal on the generator set for terminal block connections. i- PIM A A \ FwR n °z MR l I u a CUM coM. LCM 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 TPR 6803 12(11 Section 1 Installation 25 RXT ATS Generator Set 1 ~ TB1 NOTES: \ • See Figure 1-6 forterminal block location on generator set. Check the decal on the generator set for terminal block connections. 1 • See Figure 1-21 for maximum total cable length per run (3 runs with t module each shown) PIM I • See Figure 1-22 for communication connection detail (A and B. PWR and COM). r~ • 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) Connect all of the shield leads on this end to GROUND at the generatorset- , a~~ Generator Set - vwn i'! (I CAM IF - A RBUS B -~~nV PW TO GROUND 12 VDC CO 4 A t i. 3 A - 1PIM mace _ l TB1 Com Generator Set Terminal Block T81. See Figure 1-6 for location. Check the decal on the generator set for terminal block connections. 1. Splice rpseo9 Figure 1-24 Multiple Connections to the Generator Set 26 Section 1 Installation TP-6803 12111 Generator Set T81 RXT ATS i P 17M 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. LCM • See Figure 1-22 for communication connection (A and B. PWF j 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 rpaeos Figure 1-25 Accessory Module Connections (two cable runs with one and two modules shown) TP-6603 12/11 Section 1 Installation 27 RXT ATS Generator Set A and 8 A and IS PWR 2 PWR COM 2 COM I t 2 2 PIM' - A and IS PWR COM 1 2' NOTES: • See Figure 1-6 for terminal block location on generator set. Check the 2 LCM decal on the generator set for terminal block connections. Aand B • See Figure1-21 formaximumtotalcable length with 12or14AWGwire . (1 run with 3 modules shown). PWR COM • See Figure 1-22 for communication connection (A and B) detail. Connect the cable shield to ground at the generator set. 1. Belden 719402 or equivalent, 20 AWG shielded cable (use one pair): or Belden 8723 or equivalent 20 AWG shielded cable 2. 12-14 AWG wire reseoe 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 12111 1.8.7 Connect Optional Programmable 1.8.8 Connect Optional Load Control Interface Module (PIM) Module (LCM) The optional programmable interface module (PIM) The optional load control module (LCM) provides an provides two programmable inputs and six dry contact automatic load management system to comply with outputs, four of which are programmable. See TT-1584 Section 702.5 of NEC 2008 Refer to TT-1574, provided for PIM installation and connection instructions. 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 J six residential loads. Four power relays are provided for 11 management of non-essential secondary loads, and two relays are available to control two independent air 1 f1 conditioner loads. 11 2 oa`~ Two kits are available with either a prewired harness for 3 j o load relay connection, or a terminal block, The prewired it f harness requires installation of the LCM within 2 feet of the distribution panel. f~J e~ ADVS1W 1. Output connections (3 terminal blocks 6 outputs) ~x.'°'1• "t; a 2. Input connections (2 inputs) v 19 a. i n i 3. Rbus communication connection to generator set terminal block Tat;.a via~9j 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 _ h settings, use a personal computer running Kohler SiteTech software. See TP-6701, SiteTech Software Operation Manual, for instructions. A personal computer running Kohler_ OnCuef # f software can be used to actively control PIM outputs. See the OnCue Software Operation Manual for instructions. .w 4";4 PIM Connection Factory Default Setting Input 1 None Input 2 None Figure 1-29 Optional Load Control Module (LCM) Output 1 (Relay 1) Run (shown with optional pre-wired harness) Output 2 (Relay 2) Common Fault Output 3 (Relay 3) Low Battery Voltage (Program- mable) Output 4 (Relay 4) Not in Auto (Programmable) Output 5 (Relay 5) Cooldown (Programmable) Output 6 (Relay 6) Normal Source Failure (Program- mable) Figure 1.28 PIM Inputs and Outputs TP-6803 12,11 Section 1 Installation 29 1.9 Battery 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.. A WARNING particularly when it is charging. Donoti isposeofabatteryina 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 Sulfuric acid In batteries. battery charger connections while the battery is charging. Can else severe Injury or death. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing Wear protective goggles and batteries to prevent accumulation of explosive gases. clothing. Battery acid may cause Battery short circuits. Explosion can cause severe injury blindness and burn skin. 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. g WARNING 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 the starter solenoid. Do not test the battery condition by shorting the terminals together. Explosion. Connecting the battery and the battery charger. Can cause severe injury or death. Hazardous voltage can cause severe injury or death. Relays in the battery charger Reconnect the battery correctly, positive to positive and cause arcs or sparks. negative to negative, to avoid electrical shock and damage to Locate the battery in a well-ventilated the battery charger and battery(ies). Have a qualified area. Isolate the battery charger from electrician install the battery(ies). explosive fumes. Use a 12-volt group 51 battery with a minimum rating of Battery electrolyte is a diluted sulfuric acid. Battery acid 500 cold cranking amps at 0 F, The generator set uses can cause severe injury or death. Battery acid can cause a negative ground with a 12-volt engine electrical blindness and burn skin. Always wear spiashproof safety system. See Figure 1 -30 for battery connections. Make goggles, rubber gloves, and boots when servicing the battery. sure that the battery is correctly connected and the Do not open a sealed battery or mutilate the battery case. If terminals are tight, battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of Note: The generator set will not start and circuit board clean water. Seek immediate medical aid in the case of eye damage may occur if the battery is connected in contact. Never add acid to a battery after placing the battery in reverse. service, as this may result in hazardous spattering of battery acid. See the dimension drawing in Section 1.5 for the engine Battery acid cleanup. Battery acid can cause severe starting battery location on the air intake side of the injury or death. Battery acid is electrically conductive and generator set. Standard battery cables provide easy corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking connection to the battery. soda) to a container with 4 L (1 gat.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing 1 2 solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting I!r. liquid with water and dry the area. n Fz 27.0 J 1. To positive terminal on starter solenoid, 2. To ground terminal on or near starter motor. Figure 1-30 Typical Battery Connection 30 Section 1 Installation TP.6803 12(11 Use the following procedure to install and connect the 1.10.1 Regulator Heater battery. The regulator heater kit is designed for Model 20RESA Battery Installation Procedure and 20RESAL generator sets. The regulator heater kit is recommended in addition to the carburetor heater for 1. Ensure that the starting battery is fully charged reliable engine starting in temperatures below -18 C before placing the battery in service. (0 F). See Figure 1-31 for heater specifications. 2. Clean the battery posts and/or adapters if Regulator Heater necessary. Heater rating 120 VAC, 60 W Thermostat 4 C/13 C (40 F155 F) Snap action 3. Install the battery post adapters.. if needed. Pad diameter 127 mm (5 in.) 4. Place the battery in the housing. Cord length 610 mm (24 in.) 5. Connect the positive lead to the engine starting Figure 1-31 Regulator Heater Specifications battery. The regulator heater requires a source of 120 VAC 6. Connect the negative lead to the engine starting power. The generator set is equipped with one 120 VAC battery. receptacle. The kit includes an outlet splitter for powering the regulator heater and an optional Refer to the generator set operation manual and the carburetor heater. The circuit should be ground fault battery manufacturer's instructions for battery protected. maintenance instructions. To install the regulator heater kit. follow the instructions When power is applied to the RDC2/DC2 controller (that in TT-1569, provided with the kit. Figure 1-32 shows the is, when the battery is connected). you will be prompted installed regulator heater kit. to set the date and time, and then to set the exerciser. See Section 1,12 and the generator set operation 1 manual for instructions. If the battery is disconnected for service or replacement, the exercise settings on the RDC2/DC2 controller are 2 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/ 3 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. Verity that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Verity that the electrical installation complies with the National Electrical Code (NEC) and all applicable local codes. See Section 2, CM79141 Wiring Diagrams, for more information regarding 1 Regulator heater pad GM79142 generator set electrical connections. 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 20RESA/RESAL) TP-6603 121l l 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 2 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). 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/ Ipa,es battery compartment. 1. Carburetor heater (air cleaner removed to show heater) Note: Do not place the heater thermostat inside the z. Ca twretor heater power cord generator set engine compartment. The Figure 1-34 14RESA/RESAL Carburetor Heater thermostat must be exposed to the ambient air. The heater requires a continuous source of power. Plug 1 the carburetor heater into the 120 VAC receptacle provided. 1 2 3 14RESAIRESAL Carburetor Heater ' GMI"6] "514 1 Carburetor heater location 1 2 3 Figure 1-35 20RESA/RESAL Carburetor Heater - - Location on Engine (bulkhead removed 20RESA/RESAL Carburetor Heater to show heater location) GMSI9ft0 1. Power Plug 2. Thermostat 3. Heater Figure 1.33 Carburetor Heaters 32 Section 1 Installation TP-6803 12/11 1.10.3 OnCue Home Generator Connect to the Ethernet cable in the customer Management System connection area of the generator set. See Figure 1-36. Use an RJ45 inline coupler. provided with the OnCue kit, The OnCue Home Generator Management System to connect the customer's Ethernet cable to the cable in allows monitoring and control of your generator set from the customer connection box. a personal computer located in your home or at other remote locations. OnCue can also be configured to 1 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 verity the e network connection before connecting to the generator set 1. Ethernet cable for optional OnCue connection Figure 1-36 Network Connection for OnCue 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 12111 Section 1 Installation 33 1.11 Prestart Installation Check connected), you will be prompted to set the date and time, and then to set the exerciser. Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready The first setting will flash. Press the Up and Down arrow for operation Check all items in the following Prestart buttons to change the setting. Press Select to save the Checklist, setting and move onto the next. Repeat until the date, time, and exercise are set and the controller display Prestart Checklist shows the main menu. See the generator set Operation Manual for more detailed instructions to set the date and Air Cleaner. Check that a clean air cleaner element is time and set the exerciser. installed to prevent unfiltered air from entering the engine. See the generator set operation manual for Press AUTO to place the generator set controller into instructions. automatic mode. Air Inlets. Check for clean and unobstructed air inlets. Date: Setting will flash. Battery. Check for tight battery connections. Consult 050eo2011 press the y, and down arrow the battery manufacturer's instructions regarding buttons to charge the setting, battery care and maintenance. Press Select to save the Enclosure. Check that all enclosure panels and setting. T"fe internal baffling are in place. oa:alam Exhaust System. Check for exhaust leaks and blockages. Check the muffler condition. Next Exercise: • Inspect the exhaust system components for cracks, 08 31 a 12Dec2011 leaks, and corrosion. Check for tight exhaust system connections. Time Date. . and Exercise (RDC2) • Check for corroded or broken metal parts and replace Figure 1-37 Set them as needed. 1.12.2 DC2 Controller • Check that the exhaust outlet is unobstructed. To set the exerciser on the DC2 controller, first press Oil Level. Maintain the oil level at or near, not over, the AUTO to place the controller into automatic (standby) full mark on the dipstick. mode. Then press and hold the Exercise button. The generator set will start and run a 20-minute unloaded Operating Area. Check for obstructions that could cycle exercise. The generator set will run automatically block the flow of cooling air. Keep the air intake area for 20 minutes at the same time every 7 days. See the clean. Do not leave rags, tools, or debris on or near the generator set Operation Manual for more information, generator set. 1.12.3 Loaded Exercise 1.12 Set the Exerciser In order to set a loaded exercise using the RDC2 or DC2 Set the exerciser to automatically run the generator set controller, a Kohler Model RXT transfer switch must be on the desired day and time every week or every two connected. Seethe generator set operation manual for weeks. See the generator set Operation Manual for instructions to set a loaded exercise. detailed descriptions of the unloaded and loaded To set a loadedexerciseon a generator set connected to exercise operation, a transfer switch other than a Model RXT. use the transfer switch controller to set the exercise. Refer to 1.12.1 RDC2 Controller the transfer switch operation manual for instructions. When power is applied to the R DC2 controller (when the battery or the utility power for the battery charger is 34 Section 1 Installation TP6803 12111 Section 2 Wiring Diagrams Figure 2-1 lists the wiring diagram numbers and page numbers. wiring Diagram Description Drawing Number Page 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 TIr ' dr.Axt v~,y: .Air 34 ta. x.`ga -;a1k 4 -.k.<an { ~ '4' ~ y F-;. vS v. ¢ w a ? UrK S< s r y 2.tr{ ~w R. ey `p'd:~.'_. r'r r I y • y p~ J ~ ~ 3i• is t ~ t 1 ~ 5 P ~ F T~ 3~ `3 „ S i S • ~ -J-+}--.rf . y I F-, 444 vyy-~ y c I ca- * AtiWP !Q .~-c ~ { a5'v v~r¢ s~.wc w.erE xt+en hl S< i me ErraR mra, cxa.Fs ki ! t -?1'1 fJ6E K ( ~ r v'. • y y k A w - - - - - I I i~ ~ A a yRJ d . r.n' •A+f rt'i[ R?C. a i H fi4ilf T h RK R[ 3 ',W t n f4>1 II it'll o s Y rt4 r td ~~P . fie. z •1 ~ 4 1 ' a 4ys: T^aC~ . kt i r c S~yT fi 5S, y~ ~ ~q ....iP y qk rL, _ ~ ~ - nw~'~ i -I ad'I •n r ex.x i~-. , a.c- ra ur u c _ v F N 'P'F.JF YC S, ~V 1 ~V.__~ ! N` ~ vt <n st t W fem. Nws Yl4iW4~ h4 i r t IfR N1, r n-v5 s S~ .h-.i 5 4 up ynss .,p 'rl i+ . j s ,ras. z ` ;w-ss i L:kddiS•}JS • w +ct i i t~ r ~W~}~ ~ s q+uus< r~ , ~h n r«r c .ai rm r uwxw cq+ es crs r - II ~ C - - , - rzr+mew~ -H Vb•y ~ ~ B i + alb itY1M 'k'E - - - . k x3 fYd:C't~S .1t 44 e. ~ a a u i L Q t 1: D4aR~Y MYIBrW y it arsoi9r _~~,7a ~'w pFy 'R f -H v cs. Ova r 1 V r el Notes 38 Section 2 Wiring Diagrams TP 6803 12111 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere chn cubic feet per minute exh. exhaust ABDC after bottom dead center CG center of gravity ext. external AC alternating current CID cubic inch displacement F Fahrenheit. tamale AID analog to digital CL centerline FHM flat head machine (screw) ADC advanced digital control; cm centimeter fl. oz. fluid ounce analog to digital converter CIVICS complementary metal oxide flex. flexible adj. adjust, adjustment substrate (semiconductor) freq. frequency ADV advertising dimensional coon communications (port) FS full scale drawing coml commercial ft. foot, feet Ah amp-hour Coml/Rec Commercial/Recreational ft. lb. loot pounds (torque) AHWT anticipatory high water Conn. connection ft./min. feel per minute temperature cont continued ftP file transfer protocol AISI American Iran and Steel CPVC chlorinated polyvinyl chloride ram Institute crit. critical ga. gauge (meters, wire size) ALOP anticipatory law oil pressure CSA Canadian Standards al gallon alt. alternator Association g - Al aluminum gen. generator ANSI American National Standards CT current transformer gerrset generator set Institute (fomledy American cu OOpa OF ground fault interrupter °LL Canadian Association. ASA) Laboratories Underwriter's GND ground AO anticipatory only Laboratories APOC Air Pollution Control District CUL Canadian Underwriter's ~ 9 API American Petroleum Institute Laboratories gallons per hour cu. in. cubic inch 9p m gallons per minute approx. approximate, approximately cur. clockwise gr grade, gross APU Auxiliary Power Unit CWC city water-cooled GRD equipment ground AOMD Air Quality Management District cyl. cylinder gr wt. gross weight AR as required, as requested O/A digital to analog H x W x D height by width by depth AS as supplied. as stated, as DAC digital to analog converter HC hex cap suggested dB decibel HCHT high cylinder head temperature ASE American Society of Engineers dB(A) decibel (A weighted) HD heavy duty ASME American Society of DC direct current HET high exhaust temp., high Mechanical Engineers . assembly DGR direct current resistance hengine exagon temp assy. . ASTM American Society for Testing dept. department Hg mercury (element) ilia. diameter HH hex head ATOC after top tad center D1/E0 dual inleVend outlet HHC hex head cap ATS automatic c transfer switch auto. automatic DIN Deulsches Institut fur Normung HP horsepower e. V (also Deutsche Industrie hr. hour aux. auxiliary Normenausschuss) HS heal shrink avg. average DIP dual inline package hsg. housing AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating. ventilation, and air AWG American Wire Gauge DPST double-pole. single-throw conditioning AWM appliance wiring material DS disconnect switch HWT high water temperature bat. battery DVR digital voltage regulator Hz hertz (cycles per second) BBDC before bottom dead center E2PROM. EEPROM IBC International Building Code BC battery charger, battery electrically-erasable IC integrated circuit charging programmable read-only ID inside diameter, identification BCA battery charging alternator memory IEC International Electrotechnical BCI Battery Council International E, emer. emergency (power source) Commission BDC before dead center ECM electronic control module, IEEE Institute of Electrical and BHP brake horsepower engine control module Electronics Engineers blk. black (paint color), block EDI electronic data interchange IMS improved motor starting (engine) EFR emergency frequency relay in, inch blk, htr block heater e.g. for example (exonipl, gratin) in. H2O inches of water BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds hr. brass Association Inc. incorporated BTDC before top dead center EIA Electronic Industries Ind. industrial Btu British thermal unit Association int . internal Btu/min. British thermal units per minute EI/E0 end inletlend outlet int./exi. internal/external C Celsius, centigrade EMI electromagnetic interference 110 input/output cal. calorie amiss. emission IP internet protocol CAN controller area network eng. engine ISO International Organization for CARE California Air Resources Board EPA Environmental Protection Standardization CATS Category 5 (network cable) Agency J joule CB circuit breaker EPS emergency power system JIS Japanese Industry Standard cc crank cycle ER emergency relay k kilo (1000) cc cubic centimeter ES engineering special, K kelvin CCA cold crankin engineered special 9amps kA kiloampere ecw. counterclockwise ESD electrostatic discharge KR kilobyte (210 bytes) CEC Canadian Electrical Code est, estimated KBus Kohler communication protocol cert. certificate, certification. certified E-Stop emergency stop kg kilogram cih cubic feet per hour etc. et cetera (and so forth) TP-6803 12111 Appendix 39 kg/cnlz kilograms per square NC normally closed RTU remote terminal unit centimeter NEC National Electrical Code RTV room temperature vulcanization kgm kilogram-meter NEMA National Electrical RW read/write kg/ms kilograms per cubic meter Manufacturers Association SAE Somety of Automotive kHz kilohertz NFPA National Fire Protection Engineers kJ kilojoule Association Sohn standard cubic feet per minute km kilometer Nm newton meter SCR silicon controlled rectifier kOhm, k kilo-ohm NO normally open S. sec. second kPa kilopascal no., nos. number, numbers SI Sysleme international d'undo5, kph kilometers per hour NIPS National Pipe, Straight International System of Units kV kilovolt NPSC National Pipe, Straight-coupling SI/EO side in/end out kVA kilovolt ampere NPT National Standard taper pipe sil. silencer WAR kilovolt ampere reactive thread per general use SMTP simple mall transfer protocol kW kilowatt NPTF National Pipe, Taper-Fine SN serial number kWh kilowatt-hour NR not required normal relay SNMP simple network management kWm kilowatt mechanical ns nanosecond protocol kWth kilowetl-thermal OC overcrank SPDT single-pole, double-throw L liter CO outside diameter SPST single-pole, single-thtow LAN local area network OEM original equipment spec specification L x W x H length by width by height manufacturer specs specificalficti Ito pound, pounds OF overfrequency sq. square Ibm/ft3 pounds mass per cubic feet opt. option, optional sq. cm square canfimeter LCB line circuit breaker OS oversize, overspeed sq. in. square inch LCD liquid crystal display OSHA Occupational Safety and Health SMS short message service LED light emitting diode Administration SS stainless steel Lph liters per hour OV overvoltage std. standard Lpm liters per minute oz. ounce stl. steel LOP low oil pressure p, pp Page, pages tack, tachometer LP liquefied petroleum PC personal computer TB terminal block LPG liquefied petroleum gas PCB printed circuit board TCP transmission control protocol LS left side PF picofarad TO time delay L,,,e sound power level, A weighted PF power factor TDC top dead center LWL low water level ph., phase TDEC time delay engine cooldown LWi low water temperature PHC Phillips head Crimptile TDEN time delay emergency to m meter, milli (1/1000) (screw) normal M mega (10s when used with SI PHH Phillips hex head (screw) TDES time delay engine start units), male PHM pan head machine (screw) TONE time delay normal to ms cubic meter PLC programmable logic control emergency ms/hr. cubic meters per hour PMG permanent magnet generator TDOE time delay off to emergency ma/min cubic meters per minute pot potentiometer, potential TDON time delay off to normal . mA milliampere PPm pans per million temp. temperature man. manual PROM programmable read-only term. terminal max. maximum memory THO total harmonic distortion MB megabyte o byres) psi pounds per square inch TIF telephone influence factor MCCB molded-case se circuit breaker P5i9 pounds per square inch gauge 101. Tolerance MCM one thousand circular mils Pt. pint turbo, turbocharger megger megohmmeter PTC positive temperature coefficient 7p typical (same in multiple MHz megahertz PTO power takeoff locations) mi. mile PVC polyvinyl chloride OF undedrequency qt. quart , quarts UHF ultrahigh frequency mil one one of an inch qty quantity UIF user interface min. minimum, , minute e misc. miscellaneous R replacement (emergency) UL Underwriter's Laboratories, Inc. power source UNC unified coarse thread (was NC) MJ megajoule rod. radiator, radius UNF unified fine thread (was NF) ) mJ miliijoule RAM random access memory univ universal mm millimeter RBUS RS-485 proprietary URL uniform resource locator mOFm, to milliohm communications (web address) MOhm, M megohm RDO relay driver output us undersize, underspeed MOV metal oxide varistor ref. reference UV ultraviolet. undervottage MPa megapascal rem. remote V volt mpg miles per gallon Res/Coml Residential/Commercial mph miles per hour RFI radio frequency interference VAC volts alternating current MS milit standard VAR voltampe reactive arY RN round head VOC volts direct ct current ms millisecond RHM round head machine (screw) VFD vacuum fluorescent display m/sec. meters per second Fly, relay VGA video graphics adapter mtg. mounting rms root mean square VHF very high frequency MTU Motoren-und Turbinen-Union rod round W wan MW megawatt RO read only WCR withstand and closing rating mW milliwatt ROM read only memory w/ with F microfarad rot. rotate, rotating WO write only N, norm. normal (power source) rpm revolutions per minute w/o without NA not available, not applicable RS right side wt. weight net. gas natural gas RTDs Resistance Temperature xfmr transformer NBS National Bureau of Standards Detectors 40 Appendix TP-6803 12111 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. ` i H1- tr x:I'~TI vG I 'r SCALE: FULL Note: Dimensions are in mm. cM, Figure 3 Template, Electrical TP,6803 12/11 Appendix 41 KOHLER, POWER SYSTEMS KUHLEH CU oter. rsconsm. Phone 9 2 0 45-44 4 1, Fax 920455-1646 Por he nuarsst sale, service outlet in the US and Canada. phone 1-600-544-2444 Kohlel-Power com Kohler Power Systems Asia Pacilic Headquancrs TP-6803 12/11 ? )arcing Pier Road Singepoie 619158 2011 M Ko W r All npnls roeorwe. Phone r66j 6264-6422 Pax (65) H2646455