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•'
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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
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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
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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.
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y I
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crs r - II ~
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+ alb itY1M 'k'E
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. k x3 fYd:C't~S .1t
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e. ~ a
a
u i
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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