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Training Manual - CV. KOHLERINDO PRIMA

1. 12 Volt Battery Slip Rings Brush Procedure for separate excitation asss 1 Disconnect all leads from voltage regulator 2 Connect an ammeter and a 12 volt automotive battery to the and brush leads Include a 10amp fuse in the circuit in case of a shorted rotor 3 The appropriate ammeter reading should be battery voltage divided by specified rotor resistance Consult service manual for resistance specifications 4 Start generator and check that ammeter remains stable An increase indicates a shorted rotor A decreasing or erratic meter reading indicates a running open 5 If Ammeter reading is stable compare the stator winding output results with the specifications for the specific alternator found in the service manual If output readings vary from specification the stator is likely to be at fault 6 If the rotor and stator test good the voltage regulator is probably defective 48 Testing Stator The stator consists of a series of wire coils placed in a laminated steel frame The stator leads can supply voltage to the AC load voltage regulator or controller depending on the function of that output coil Prior to testing inspect the stator for heat discoloration and visible damage to housing exposed coil windings and exposed varnished areas of frame laminations If visible damage exists the stator will need to be repaired or replaced Checking Stator Continuity and Resistance Tools required
2. Not necessary for maintenance free batteries R Replace as necessary 38 3 Years gt Weekly Quarterly wo e a EI a bei 6 E a Alternator Design Mechanical alternators or generators that produce an AC output are either the rotating armature or the rotating field design and require 3 basic things 1 Conductors 2 A magnetic field 3 Movement between the two 1 The conductors are copper wires wound in slots of laminated steel referred to as the armature and provide the generated output voltage 2 The field is the invisible magnetic force produced by electro magnetic pole pieces 3 Movement between the field and conductors is necessary to create current flow in the armature windings and is usually provided by a gas or diesel engine Kohler residential generators are of the rotating field design Rotating Field Generators Alternators used on most generator sets today are of the rotating field design The magnetic poles of the rotor rotate past the armature windings of the stator The rotor is energized with a DC field by some type of excitation As the field rotates the magnetic flux lines cut the conductors which are distributed so as to induce a sinusoidal voltage in the stator The stationary stator also allows for easy reconnection of the windings to permit various three phase or single phase voltages 39 Alternator Current Flow Stationary Windings Rotating
3. Coolant s Pressure Level Temp Pick Up EdOO Digital Digital Digital n a _Ed01 Digital Digital Analog n a Edo2 Analog Digital Digital n a Edo3 Analog Digital Analog n a Ed04 Digital Digital Digital X _ d05 Digital Digital Analog X Bang Analog Digital Digital Xx EdO7 Analog Digital Analog X Edos Digital Analog Digital n a Edog Digital Analog Analog n a Edio Analog Analog Digital n a Ed11 Analog Analog Analog n a Egi2 Digital Analog Digital X Ed13 Digital Analog Analog Xx Ed14 Analog Analog Digitel x Edis5 Analog Analog Analog x Bt12 12 VDC Bt24 24 VDC Cn00 No Comm Cn01 SAE J1939 Cn02 Future 62 Dynamic adjustments The generator must be running to make dynamic adjustments such as voltage raise and lower or speed raise and lower To enter the dynamic adjustments menu 1 Start the generator and press the SELECT button until the software version is displayed 2 Continue to hold the SELECT button and press the down button and then the UP button repeat this 3 times 3 If done correctly you will enter the first menu Voltage adjust Voltage Adjust coarse The course voltage adjustment is your first setting When in the menu you will notice the third digit flashing Adjusting the number up will raise the outpu
4. Use extreme care when handling storing and us ing fuels LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check LP liquid withdrawal gas fuel system for leakage using a soap water solution with fuel system test pressurized to at least 90 psi 621 kPa Use a soap solution containing neither ammonia nor chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble 11 A WARNING Sulfuric acid in batterles Can cause severe Injury or death Use protective goggles and clothes Can cause per manent damage to eyes bum skin and eat holes in clothing Battery acid Sulferic acid in batteries can cause severe injury or death If battery acid is splashed in the eyes or on skin immediately flush the affected area for 15 minutes with large Quantities of clean water In the case of eye contact seek immediate medical aid Never add acid to a battery once the battery has been placed in service Doing so may result in hazardous spattering of electrolyte Explosion can cause severe Injury or death Battery gases can cause an explosion Do not smoke or permit flame or spark to occur near a battery at any time particularly when it is being charged Avoid contacting terminals with tools etc to prevent bums and to prevent sparks that could cause an explosion Remove wristwatch rings and any
5. Alternator Alternator General Troubleshooting This section will cover general trouble shooting fundamentals used when diagnosing alternator problems When servicing a generator use specified service manual and follow all safety precautions Follow the troubleshooting flowchart to determine the cause of no or low AC output from the generator Generator has no output Separately excite generator Generator has output Check SCR module PowerBoost circuit wiring Digital regulator Generator has no output Test stator Test rotor Disconnect generator starting battery before testing any parts of the alternator assembly 47 Alternator Separate Excitation To determine the cause of no or low AC output separately excite the generator The generator SCR module Kierch field rotor may be magnetized using an alternative DC power source 12 volt automotive battery and following the procedure below While separately exciting the generator to dis determine the presence of a faulty voltage FNC 7 regulator it is possible to determine if a running Remove Leads fault exists in the rotor and or stator A generator component that appears good while static stationary may exhibit a running open or short while dynamic moving This fault can be caused by centrifugal forces acting on the windings while rotating or insulation breakdown as temperatures increase
6. Dependent on voltage Rotor resistance ohms cold An Stator resistance ohms cold Leads 1 2 3 4 0 07 11 44 0 14 55 66 0 70 Stator output voltage with separately excited rotor using 12 volt battery minimum Leads 1 2 3 4 132V 11 44 264V 55 66 145V Rotor field voltage current readings at rated output voltage hot No load 8V 2 5 amps Full load 47V 7 4 amps Brush length new 19 05 mm 0 75 in Most ohmmeters do not give accurate readings when measuring less than 1 ohm The stator can be considered good if a low resistance reading continuity is obtained and there is no evidence of shorted windings discoloration Do not confuse a low resistance reading with a reading indicating a shorted winding Specification Engine Specification The 8 5 12RES generator sets are equipped with Dependable maintenance free electronic four cycle twin cylinder air cooled Kohler ignition engines Some of the engine features include Digital Spark Advance Module DSAM optimizes One side serviceability of air cleaner carburetor engine timing for natural gas or LP fuel 12RES oil fill dipstick and oil drain only Efficient overhead valve design and full pressure Parts subject to the most wear and tear made lubrication for maximum power torque and from precision formulated cast iron reliability under all operating conditions Hydraulic valve adjusters to eliminate the need
7. ENOJO a G aai sN050 11d c l ci ta 3SVHd JIONIS SRS AQV 338 SNOLLOINNO9 8O1V83N39 YOY 31ON HOER Agave a avis a HOLAS SE O o e Hous er Eu 19 895 9 d ONY STYNIN331 z ICAO YIMOILSNO Al y Z td Ltd Late GE iad lt A fed Dm g LCA 02 02 SNOILISNNOO uaWOISNS N gos z 1vIS EE kt 1983 wo D d Aal ul z53v_u9s 99 895 ad 6 vld vie 3 N O N 9 14 OU e S td 01 vi ido at 4 td 01 82 18 Nid SN0IIS3NN05 9d 6 14 a 8 8 13 ol 3NOMJINNO Sd yore Sd ai rd CL 1 R ft ENOJO U VE Fy RL Lal G eren is 983 EY bed 6Z 1d 028 CL NO N AS VER LG Z LaiN 3NISN3 a NMOHS 300 H3MOd MOT SEB9 AQV JJS SNOMIZNNOD YIJANFT d YOY ALON xoa JIVOYJINO9 001Z30V 519 QLWIASNINA Lan CaLWINSNINA 1000 go ivi Z10320 3983 a Sd ins v sa asm 1 97 ca r 9a I Igel 2 90 2 1d g vt a ld Controller To read the point to point diagram start at any device in the diagram The wire at the component will have a wire number followed in parentheses by the component the wire goes to and to where it terminates Reading the Diagram You want to check the control voltage to the Start Relay SR what termination points should your meter leads be on Field flashing leads terminate
8. Magnetic Field Alternator Alternator The Alternator is of the Rotating Field design and consists of two major components the Rotor and Stator The Rotor which is located within the Stator is of the 2 pole design and is directly coupled to the tapered engine crankshaft stub with a thru bolt Excitation slip rings are mounted outboard of the end bearing and accessible from the exterior of the end bracket The fan is permanently mounted to the rotor shaft The Stator contains the copper windings which provide the load current and is assembled to the engine adapter with an end bracket and overbolts The 4 lead stator is wound for single phase applications only and is factory connected to provide a 3 wire 110 220 to 120 240 volt supply The DC excitation to the rotor slip rings is supplied by an adjustable static exciter regulator THRU BOLT 40 Alternator Stator 120 240 v 3 Wire 110 220 v 3 Wire The 4 lead stator is factory connected to provide two low voltage 110 120 circuits and one high 220 240 voltage circuit The rated load amps can be divided between these three circuits A 2 pole circuit breaker is provided for load disconnect Customer load connections are made at the breaker Most Standby applications require a 240 volt circuit including the G120 Automatic Transfer Switch Stator leads 11 44 are common to stator leads 1 and 4 and provide the voltage sensi
9. Ohmmeter Megger The example illustrates a single phase alternator Note Refer to service manual for all specifications with reguards to winding resistance values Continuity 1 To check stator continuity set ohm meter to a low resistance setting This test will check if any coils are shorted to each other or there is a short to ground 2 Dissconnect all stator leads prior to performing measurements Leads1 2 3 and 4 are the generator output leads Leads 11 44 are the voltage regulator sensing Leads 55 66 are control power for the excitation 3 Check continuity of all windings the meter should show continuity when checking between leads 1 2 3 4 55 66 4 Check for continuity between coil groups meter should show no continuity If the meter indicates continuity this means the two coil groups are shorted together 5 Check continuity between each coil group and the frame of the stator meter should show no continuity If the meter shows continuity this indicated the coil is shorted to ground Alternator Resistance Most ohmmeters will not provide accurate readings when measuring less then 1 ohm which is typical for a stator winding The stator can be considered good if a low resistance reading is obtained in each coil group and there is no evidence of an internally shorted winding heat discoloration 11 44 49 Megger Testing The purpose of insulation is to prevent shorting between the w
10. emergency source or generator set must also provide this same power A diagram is provided inside the ATS enclosure Neutral to aid installation of line power connections Connection push on tab terminals are provided at each of these terminals for controller voltage sensing and the transfer operator coil supply Building Load Connection NA NC LA LC EA EC The contact assemblies are not identical for the 100 amp and 200 amp contactors Refer to the Service manual when performing ser vice work 68 Automatic Transfer Switch Contactor These contactors are electrically operated double throw switching devices The Normal and Emergency power sources are connected to stationary contacts and the movable Load contacts assembled to a pivot shaft This provides a mechanical interlock to assure both power sources cannot be connected simultaneously N E Two electric solenoids operate the linkage to flip the moveable contact between the power sources A complete transfer occurs within 50 milliseconds The solenoid is powered by 120 vac rectified line voltage from the source to which the load will be transferred Normal or Emergency A full wave bridge assembly rectifies the AC line voltage to DC Input is to terminals labeled AC There is no polarity preference of the solenoid to the and rectifier output terminals The DC Voltage to the solenoid coil is supplied only momentarily The circuit is disrupted
11. Chart Home Appliances Wattage Requirements This sizing chart is intended to help you estimate the essential wattage requirements for the appli ances you wish to use during an emergency utility outage Your total wattage requirement will help determine which Kohler residential generator set system will best serve your needs When selecting your essential appliances please note the following 1 Wattage loads for appliances are calculated two different ways a Resistive Loads Circuits that do not have electric motors ovens toaster TV lighting b Inductive Loads Circuit that have electric motors AC dryer washer furnace sump pump Starting wattage additional wattage is required to start electric motors used in home appli ances 2 These estimates are intended to assist in the specification phase of assessing your generator set requirements Actual appliance wattage will vary depending on the appliance manufacturer and application 3 By staggering when you use specific appliances the chart allows you to determine practical usage during an emergency utility failure Typical AC Electrical Requirements for Residential Installation Use the chart on the next page to calculate your estimated wattage After you have your total estimated wattage calculated go back and determine from a practical standpoint those appliances you would actually run need at the same time Keep in mind you can stagger appliance usage for example tu
12. DOP PIN A SURI GEMLRATOR OPER RTB M 2PXX OJA When in course Regulator Gain adjust the third digit will flash When in fine adjust the fourth digit will flash 63 Volts Hz The Volts Hz adjustment for the voltage regulator comes preset from the factory and typically no adjustments should or need to be made The default setting is 4 2 voltage droop The programmed roll off point for 60Hz applications is 58Hz for 50Hz applications it is 48Hz When in the Volts Hz menu the fourth digit will represent the percentage of nominal voltage droop Example system voltage 240 v system frequency 60 Hz roll off is 58Hz Volts Hz setting is 4 2 of nominal 4 8v per cycle If the generator frequency would drop to 50Hz that would be a 8Hz drop after roll off 58 50 8Hz x 4 8 V per cycle 38 4 v Nominal voltage 240 38 4 201 6 v 50Hz The Volts Hz setting allows the generator to respond quicker to heavy load changes Should the frequency drop due to an increased load the voltage regulator will automatically decrease voltage thus shedding kW and allowing the generator to recover to the proper frequency and voltage output When the Volts Hz is set incorrectly response to load changes will take longer then desired When set point is selected press SELECT to advance to the Governor Speed menu Controller 0 No droop 1 0 5 of nominal 2 1 0 of nominal 3 1 5 of nominal 4 2 0 of nominal 5 2 5 of nomina
13. at RIB T1 and T2 What is RIB Looking at the P14 connector plug where does wire 71A terminate List the starting and ending point You need to check the magnetic pick up voltage How would you do this What voltage should be measured during crank What wire energizes the FV What is the point to point connection for LOP list the starting and ending points At what pin location does positive voltage enter the relay control board Is this a fused input What does the F1 fuse provide protection for To change the ignition timing of the CH740 engine when running on natural gas the 65 wire should be connected to ground T or F 10 Is wire 14P a fused power source What is the purpose of 14P 58 System Configuration Shipped with application program this means typically you will never have to enter the system configuration menu of the ADC controller Reasons to go into the systems configuration may be controller replacement voltage or frequency adjustments gain adjustment reconfigure stator output voltage System configuration includes genset model phase frequency voltage unit utilization marine mobile standby unit data analog inputs digital inputs magnetic pick up battery voltage 12 or 24 VDC communication setting Dynamic settings voltage adjust frequency adjust gain adjustments volts Hz adjustment Password Protection The ADC configuration menu can only be entered with the use of a password
14. by cam actuated limit switches after full travel of the solenoid plunger Coil varistor and bridge rectifier are assembled as one piece Disassemble unsolder the components before testing for an open or shorted circuit 69 Automatic Transfer Switch Contactor When the contactor is in the Normal position the SCN SCE operating lever allow limit contacts SCN to be open and SCE to be closed The opposite occurs when in the Emergency position The limit switch assemblies are factory set and nonadjustable They are wired in series with control relay contacts NR and ER The contactor is always mechanically latched in position after a Operating Lever transfer During installation or when servicing the contactor a manual transfer can be performed by using the manual operating handle provided ELECTRICAL POWER MUST BE DISCONNECTED FROM THE CONTACTOR WHEN MANUALLY TRANSFERRING 70 Automatic Transfer Switch Harness The contactor assembly is interconnected to the controller by a harness and plug connector Connections at the contactor assembly are made with push on tab terminals A 15 pin plug connector designated as J1 is attached at the controller end of the harness Use caution when testing for voltage or continuity between plug pins Any voltage present on the normal or emergency contacts is also preset at the connector pins 71 103 TS SCN NLI 41 12 104 31 10 e J1 7 E
15. optional toggle switch between terminals 2 TEST and 3 GRD of the TB2 terminal strip on the Con troller board A normally closed push button or momentary toggle is recommended Opening the switch contacts will simulate a loss of the Utility power and initiate an engine start up and transfer of load to the Generator set 1 2 3 4 5 6 TB2 esas lu S NSC TEST GND ESC GNO 3PH 3 ley ETA ni FIYA 75 Automatic Transfer Switch CONTACTOR GND SR e Wu o O EU NL2 o See HA m z3 3 3 z z w ui NL2 JUMPER EL2 x i 2 Am D I ED J1 14 Aut 10 n atra 1 3 Autres Pi P1 15 P1 7 P1 13 tee TB4 P1 14 P1 10 PA P14 P1 3 Pi 6 12 ie LOGIC BOARD NR NR ER AM NR NR ER d N It b 9 o lt o 8 0 00 E E seg 263832 s s JS JP1 3 a JP4 o JPS D pe Pa Paso a s F 3 F 3456 pa os 8 P2 3 32 4 Te Je I z TEST ENGINE SWITCH START E SEE NOTE 1 SEE NOTE 2 NOTE 1 TEST SWITCH PROVIDED BY OTHERS CUT JP2 WHEN INSTALLING 2 ENGINE START CONTACTS RATED 30 VOLT 1 AMP WIRING PROVIDED BY OTHERS 3 CONTACTOR SHOWN IN NORMAL WITH NO POWER APPLIED 4 FOR WIRING DIAGRAM SEE GM25943 LEGEND CE TRANFER COL EMERGENCY TRANSFER CN TRANSFER COIL NORMAL TRANSFER ES3D ENGINE START DISABLE ES3 4 ENGINE START ER EMERGENCY RELAY ERD EMERGENCY RELAY DISCONNECT ESC EM
16. the pipe for a gaseous system a few things need to be considered the type of fuel the distance it must travel from gas meter or tank to the fuel shutoff solenoid and the amount of fuel consumed by the engine To figure the correct pipe size for a specific installation refer to the chart and follow the procedure outlined 1 Determine length of pipe between gas meter tank and fuel shutoff solenoid at generator set Example 35ft 2 Find figure closest to pipe length in Length of Pipe column on chart Example For 35ft it would be 40ft 3 Refer to fuel consumption from the generator specification sheet Note type of fuel and consumption of fuel at 100 load Example The 8 5RES for natural gas operating at 100 full load uses 132cfh cubic feet per hour 4 Refer to correction factors below Locate factor for specific gravity of fuel used Example natural gas specific gravity 65 correction factor 962 5 Divide consumption figure 132cfh by the correction factor 962 132 962 137cfh 6 Move vertically across page to determined point in length of pipe column 40ft go down column and stop at first figure equal to or greater then corrected consumption figure 137cfh 7 Move to left column from figure 137cfh to determine correct pipe size The correct pipe size for a 8 5RMY with a pipe run of 35 ft should be 3 4 inch Correction Factors Fuel Specific Gravity Factor Sewage Gas 0 55 1 040 Natural Ga
17. the recommended intervals To aid in operating under high ambient conditions an oil cooler is provided Heat is transferred to the fins and dissipated in the air flow The engine operates with a partial vacuum in the crankcase This is controlled by a PRESSURE breather assembly consisting of a reed SM valve A pressurized crankcase due to a faulty ei ose or clogged valve could cause oil leaks at seals and gaskets A hose attached to the valve vents the crankcase fumes to the mixer air intake for ingestion into the combustion chambers A pressure switch is installed in an oil passage in the breather cover to protect the engine in the event of a fault which would cause oil pressure to drop to an unsafe operating level Contacts in the switch will close when the pressure drops below 3 to 5 psi and will initiate an engine shut down 32 Ignition System Ignition System CH20 The CH20 engine feature dual capacitor discharge ignition modules to fire the two sparkplugs They are installed on the cylinders in close proximity to the flywheel A permanent magnet is located on the flywheel which is keyed to the crankshaft providing a fixed timed ignition CH20 As the magnet approaches the L1 coil a potential is generated which is rectified by the D1 diode and stored in the C1 capacitor Further rotation of the flywheel causes a current to be induced in the L2 coil which triggers the SCR discharging the ca
18. x P1 GA era sz P2 5 F ER ERO TB4 NR LED ER LED TBS A 353529 73 Circuit Board TB3 Connections to the engine start circuit are made to terminals 183 A dry set of K1 relay contacts will close between terminals 1 amp 3 when an engine start is required ES LED The ES LED will light when the K1 is ener gized NR LED The NR LED will light when the NR relay coil is energized ER LED The ER LED will light when the ER relay coil is energized NA LED The NA LED will light when the Normal source voltage is at the acceptable level EA LED The EA LED will light when the Emergency source voltage is at the acceptable level NR Normal source control relay ER Emergency source control relay R20 EUV Emergency source voltage pick up adjust Factory set R15 NUV Normal source voltage pick up adjust Fac tory set Automatic Transfer Switch ENGINE START TERMINALS 3 4 ES3 ES3D ES4 T 1 K1 5VDC 5v logic voltage test point P2 Plant exerciser selector switch harness connec tor TB5 Power supply and relay status terminal strip TB4 Transfer disable option jumper terminal strip TB2 Test switch option terminals TB1 3 phase sensing module terminal strip JP2 Test switch jumper 74 Automatic Transfer Switch Neutral Ground An equipment ground terminal and Neutral bus is provided in the enclosure TIGHTENING TORQU
19. 20 rpm and 3776 rpm This adjustment is made through the advance programming menu of the ADC controller Speed Gain has an adjustment of 5 Adjustments are made through the advanced setting menu in the ADC program CUSTOMER PROVIDE REMOTE START SWITCH ADC2100 FIELD DRIVE PLUS FIELD DRIVE MINUS GOVERNOR 1A P1 5 GOVERNOR 1B P1 4 P16 1 G BLK G BLK G BLK F RED 9 EE RED F REL P6 3 BLK GRN 1A P6 2 18 P6 4 GOVERNOR 2A P1 6 e 24 GOVERNOR 2B P1 7 OR ENGINE START CONTACTS ON TRANSFER SWITCH _ weu 4 o P1 26 REMOTE START STOP 2 Li A 3 e P1 25 REMOTE START STOP 1 LOP PoP OL PRESSURE SWITCH mag pick up input ou RA e See Bern el P1 29 VR SENSOR HIGH HEINZ vi a 5180 P1 18 GROUND mE A nite P1 8 COOLANT TEMP SENSOR HIGH da a 1d CLlsx spi 9 COOLANT TEMP SENSOR LOW CTS ML MM 52 P1 21 GROUND 31 P6 1 B Stepper motor Lube System Lube System The Kohler Command engine features a pressurized oil lubrication system The gear driven pump is located in the sump and supplies approximately 25 35 psi of lubricant to the internal components at nominal engine speed Pressure is limited by a relief valve A dipstick is provided for periodic oil level checks As with any engine do not operate with the level below or above the designated markings Itis also very important to adhere to a good maintenance program Replace the oil and filter at
20. E VALUE a NEUTRAL BUS CONTACTOR See Engine Exerciser Feature To insure the generator set will start and perform when needed a circuit is provided which allows the engine to automatically start and run for 20 minutes a week The engine will run unloaded The switch will not transfer unless a power failure occurs during the exercise period The day and time of day that the feature was set will be the day and time the exercise will occur each week until reset or disabled A 3 position switch provides the setting and disabling functions SET fa 0 RUN O 8 DISABLE SET Placing the switch in this momentary position will set the start time as well as the day of week the exercise will occur RUN The switch will return to this position when released from setting This is the normal position when the weekly exercise option is selected DISABLE Ifthe exercise option is not desired it can be turned off when left in this position The disable position effects the exercise option only It has no effect on transfer switch operation The internal exercise clock requires either the Normal or Emergency source to be present to maintain its memory If both sources are absent for longer than 90 seconds the time and day selected will be lost and automatically reset to the time and day power was restored Transfer Test Switch The complete system can be tested by remov ing the JP2 jumper and installing an
21. ERGENCY SOURCE CONTROL J JACK JP ON BOARD JUMPER NR NORMAL RELAY NRD NORMAL RELAY DISCONNECT NSC NORMAL SOURCE CONTROL Pm PLUG RE BRIDGE RECTIFER NORMAL TRANSFER RN BRIDGE RECTIFIER EMERGENCY TRANSFER 1 EXERCISER MODE SWITCH SCE EMERGENCY COIL CLEARING LIMIT SWITCH SCN NORMAL COIL CLEARING LIMIT SWITCH TRY TERMINAL BLOCK 76
22. Electronic governor to ensure AC power output for valve adjustments is maintained at desired frequency Fuel systems that allow fuel changeover from Overspeed shutdown to prevent governed natural gas to LP vapor and vice versa while frequency from exceeding 70 Hz maintaining CARB certification Low oil pressure cutout to prevent failure Engine Specification 8 5RES 60 Hz 12RES 60Hz CS Ga I ek A A Number of cylinders a EEN Compression ratio AOC Displacement cc cu in 624 38 0 725 44 0 Rated power propane fuel kw hp 5 15 4 17 6 23 6 Bore x stroke mm in 77 x 67 3 03 x 2 64 83 x 67 3 27 x 2 64 Stoel State Cyinder head material ee Lubrication system Full pressure Ol capaciy wanej LG RO de Cylinder block material p a psi Spar ening torque Nm ft ib 24 4 29 8 18 22 2 a Smart Spark Ignition system Capacitor Discharge Capacitor Discharge Starter motor Electric solenoid shift Cooling system 2 l ressure kP LP natural gas minimum supply pressure y in H20 oz in 2 7 11 4 6 k plug tight Specification Controller Specifications Advanced Digital Controller LED display Run time hours DISPLAY REMAINS ACTIVE Crank Cycle Status per mee ya Diagnostics Application Software Version LED display faults High Battery Voltage Low Battery Voltage Low Oil Pressure Overcrank Overspeed DEFINITION Overfrequency Auxiliary Fault
23. MA 62 10 he day zng gt MOT MOES YA ALL al leo A IWER dd BZ HONH3AQS 1 90 Yz 9 Ld WZ YONHIADO ISCH z HOLMS FUNSSIMA NO t td ci lo F ael Late onay ek HEN J ZAOLS 1MWIS UONIY 97 108 pt y Mi NYD ar Si Yi we 9d Y ld 81 YONYJADO id YL HONNIADO d NOL O3 d Y 4 4 D 4 SNNIN BAO MOL X X Fold OHINOO 8 9 8 9 gy 8 9 SMS Ant TRL EEN 12 99 yo 1 99 AMAN ONIONIA IN Am IWA DW 00 55 00 55 SC om ee aan ONKINIM um ONISNIS HSV S N E d 103135 KION Y3MOd SNOMNUNOD Z d e NORD Ed he 14 Weu za v eu 2 9 6 ttd AMS VOYINOS ATH HSY S id fee A AND HSY HIM ATE NAY XNY TINA b tdbe NOL i td 100 AY138 BNI YOULNOD AY Lu HOD Zrlde SE 100 1171 W nn ltd INO AJY BILNWIS TAR Srt TIOMIN0O AW 1UVIS Ei Wu CH NOUINSI IVBA 9 vidje 24d onda OND g rid e N91 ala NOL EE LI HOLAS W34SNYMI NO_SLOVINOO LUVIS 3NION3 YO HOLAS LVIS 31038 sy ONY St SOGAO8d YINOLSNI OL Z SJA Y3MOd MOT Z DL L M3dNn0C HU3MO SRONNUNOD L gon za Toon SNOMO3NNO9 dd O AVBA 97 1 A ONNOHD Z id ee N vo 4 L ee pl 55 Controller Understanding the Schematic 1 Fused battery power enters what pin connections to the relay control board 2 Field flashing is controlled by
24. NL2 41 15 SS NA TS N EN TS N 107 TS CE 108 41 1 AAR N L EL2 J1 6 EL2 41 14 107 TS SCE G _ _________ EL1 1 3 NEUTRAL EN TS SCE NO EN NN TS SCN NO NL2 TS NL2 NL1 TS NL1 EL2 TS EL2 ELA TS EL1 91901 Automatic Transfer Switch G220 Controller The decision making process of the automatic transfer switch is performed by the Controller The controller monitors the systems electrical sources and logically energizes control relays for engine starting and switch transfer Voltage supply to the transfer mechanism is provided by the source to which the switch is transferring The Utility is the NORMAL or Primary source and the control circuit will always seek the normal source The controller is sensitive to the system voltage Transformers reduce the line voltage to low more manageable voltage for the sensing and control circuits Logic circuitry is both relay and solid state STANDARD FEATURES Normal and Emergency voltage sensing is factory set at 160 vac drop out and 190 vac pick up DROP OUT If the Normal utility voltage fails completely or drops below 160 volts line to line a signal for an engine start would be initiated PICK UP When the Emergency Generator voltage reaches 190 vac A transfer to the Emergency source will be initiated The same specifications apply for pick up on return of the Normal source voltage 190 vac TDES 3 seco
25. Overvoltage Crank Cycle High Battery Voltage Undervoltage High Engine Temp UnderFrequency Low Battery Voltage Low Coolant Level Password Protected Loss of Coolant Run Off reset Auto mode Low Oil Pressure SES Over Crank Digital lsochronous Governor Over Frequency D Over Speed Digital Voltage Regulator Over Voltage Cyclic cranking Under Frequency Under Voltage OFF RESET Power requirements Current 250 mA O 12 VDC 125 mA 24 VDC 23 Air Intake Cooling The enclosed unit is cooled by a directed air flow system Two fans one attached to the engine flywheel and the other to the alternator rotor draw in ambient air to cool the engine alternator and controller as well as purge the compartment of hot air The engine fan draws air from the housing inlet and forces it across the cylinder cooling fins A portion of air is also directed through the control ler An opening in the controller shelf provides air flow for the voltage regulator The Alternator fan draws cool air into openings in the end bracket to cool the rotor and stator Air Inlet Exhaust Air 24 Air Cleaner A portion of the outside ambient air is directed from the flywheel fan to the Gas Air mixer carburetor for combustion The air is first filtered by an oiled foam precleaner and replaceable paper element air cleaner It is important that the filters are serviced at the recommended scheduled times and that th
26. Training Manual Residential Generator Sets 8 5RES 12RES G220 ATS KOHLER POWER SYSTEMS Sis Table Of Content Introduction E 2 6 e 7 13 System Concept A A 14 19 PECADOS nicas 20 23 elt 24 25 A u z ene R unas sassa E 26 30 E A ha aea i 31 TA 32 Ignition SOM eo 33 34 Starting SySteM A 35 36 Battery el Le EE 37 Maintenancoe o 38 Alternator A e AAA 39 51 nn assays asas asus 52 66 Automatic Transfer Switch 67 76 Introduction This manual covers operation troubleshooting and features of Kohler Commercial Residential Generator Sets This manual is only intended as a training guide and is to be used as a supplement to classroom material This is not a service manual and does not contain all available product information Do not attempt to service generator sets without consulting the service manual and following all safety warnings Pictures illustrations and wiring diagrams in this manual are only representative of the various models and may differ slightly even within the same model designation series This manual is not intended as an installation or troubleshooting guide Kohler Company History Founded by John Michael Kohler on Dec 3 1873 Kohler Co has grown to become the nation s largest manufacturer of plumbing and specialty products as well as a major producer of generators and
27. Using the password 1 Hold the select button and toggle the start switch to run the generator will not start After approximately 5 seconds the software version will be displayed 2 Continue to hold the select button and press the down arrow then the up arrow do this 3 Select times 3 If performed correctly 4 LED segments will be displayed This display is the first menu for configuration setup NY Down Note The display will revert to run time hours after 1 minute of non use and only saved settings will remain 59 Controller Controller Configuration Menu s Uu0X Unit utilization phase frequency voltage Uc0X Unit configuration marine mobile residential EcXX Engine configuration generator model Adnc Advanced Configuration Level EdXX Engine data Advanced Config Level Bt12 or Bt24 Battery voltage Adv Config Level Cn0X Communication Setting Adv Config Level SAVE Select X numeric value To navigate the menu s Once in a menu use the UP arrow to toggle through the menu settings if you pass over a data selection use the DOWN arrow to go back When you find the data selection in a particular menu press the SELECT button this will advance you to the next menu Whatever data selection you had displayed is what will now be programmed into your system configuration Use the SELECT button to navigate through each menu and the UP and DOWN buttons to navigate wi
28. a liquid in pressure tanks which makes it easily adaptable to stationary generator applications where complete independence of a fuel source is required LP gas is propane butane or a mixture of the two gases The ratio of butane to propane is especially important when an outdoor tank is used LP gas suppliers may supply the tank in warm summer months with a mixture composed mostly of butane this mixture my work well in summer but may not provide sufficient vaporized pressure at cold temperatures below 32 to start and run the engine Check with you LP gas supplier for mixture content when hard starting symptoms exist Boiling Point Initial End Btu s per Gallon Net LVH Gallon Gross Cubic Foot Gas Density Cubic feet of Gas per Gallon Liquid Wel DS per Gallon Liquid Octane Number Research Motor Fuel System The heating value for propane is 2 516 BTU per cubic foot with a boiling point of 44 F and butane is 3 264 BTU per cubic foot with a boiling point of 32 F Inlet pressure into the secondary regulator should be 4 6 ounces per square inch or 7 11 inches water column Outlet pressure to the carburetor will be a negative pressure of about 11 2 inches water column Physical Property 60 F 15 C eran State 28 44 F 42 C 44 F 42 C Fuel System Pipe Size Requirement for Gaseous System When installing the generator and laying
29. akage Insulation fire hazards Hangers and supports Yearly Monthly Yearly Yearly Yearly Battery charger operation charge rate if equipped Remove corrosion clean and dry battery and rack D m O E OO O x E lt m JHE m S 4 216 3 3 r O oO EA 3 3 3 om v lt P 3 g 2 3 S H D a E o Clean and tighten battery terminals Battery electrolyte level and specific gravity AC Electrical System Visible wear or damage Wire abrasions where subject to motion Tighten control and power wiring connections Wire cable insulation breakdown Quarterly Yearly Weekly Yearly or 100 hours Yearly or 300 hours 500 hours Weekly Visible wear or damage Air cleaner service Spark plugs Replace stepper motor coupling and bushing Compartment condition D m Oo 3 3 z o D e a 2 2 2 a 3 e 3 Monthly Weekly Remote control Run generator set Generator Visible wear or damage Quarterly Weekly Yearly Exercise generator set Rotor and stator Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected General Condition of Equipment Evidence of vibration leakage excessive noise temperature or deterioration Interior of sound enclosure x Contact your local distributor dealer for parts or service X Action
30. anger is used to indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the warning is ignored WARNING Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate the presence of a hazard which will or can cause minor personal injury or property damage if the warning is ignored NOTE Note is used to notify people of installation operation or maintenance information which is important but not hazard related Safety Safety decals are affixed to the generator set in prominent places to advise the operator or service technician of potentially hazardous situations The decals are reproduced here to improve operator recognition and thereby increase decal effectiveness Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and rou tinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Never operate the generator set inside a build ing unless the exhaust gas is piped safely outside Never operate in any area where exhaust gas could accumulate and seep back inside a potentially occupied building Avoid breathing exhaust fumes when working on or near the generator set Carbon monoxide is particularly dangerous because it is an
31. art and building load transferred to the generator if the utility supply fails or falls below a specified level When utility returns the ATS will transfer back to utility and allow the generator to go into a cooldown mode before shutting down the generator The system is designed to require no manual intervention from the homeowner when operating automatically Note when planning an installation of a home standby generator and ATS the installer must follow all municipal codes for the region Installers must be familiar with and comply to all Natural Gas or LP fuels codes as well as all electrical safety codes 14 System Concept Generator Disconnect Electrical Distribution Panel Utility Disconnect Essential Loads SN oy oy oy Dei Oe Dei Essential Loads Panel u Utility Supply Prior to installing a Kohler power system the installer should carefully determine the size generator and ATS required The generator will Main Panel on Essentia be sized to meet one of two electrical designs Essential loads application shown above or Whole House Power The essential loads refers to providing power for those devices that a customer designates as essential during an emergency utility power outage Sump pumps furnaces air conditioning refrigerators freezers and security lighting could all be considered essential Circuits 100A Switch During installation these devices are wir
32. ault AF GRADA High Engine Temperature HE Low Oil Pressure LOP RUN P Overcrank OC Overfrequency OF Overspeed OS Overvoltage OU Underfrequency UF Undervoltage UU System Warnings High Battery HB Low Battery LB The start selector switch is a three position device The generator can be started locally by placing the switch to RUN When an Automatic Transfer Switch or remote start is utilized the generator will be signaled to start when the selector switch is in the AUTO position and a contact closure occurs across leads 3 and 4 The generator will shutdown when the switch is placed in the OFF RESET position 52 Controller ADC Interface The ADC controller utilizes 3 plug connections to control the interface between the controller engine and alternator P 1 plug The P 1 plug is the termination point for all DC connections The DC inputs include Low Oil Pressure Coolant Temperature Remote Start Battery positive and negative and the i e mag pick up input Ach The DC outputs include the 71N starter Ce relay 70N run relay and DC output to the P 16 plug governor stepper motor The P 15 plug is the input connection for AC sensing The ADC controller uses this input for voltage regulation and a secondary means of crank disconnect The P 16 plug connections are for the PowerBoost winding input and the field drive outputs to control excitation The P 16 plu
33. considered as critical loads and therefore need not be powered by the generator An emergency supply of 8 5 to 12kW in most cases is adequate There are various design schemes that an electrical contractor can offer that can meet customers particular needs System Concept Generator Disconnect i 230 5 Electrical Distribution 3 a S gt Dodo Cie Ce o 0 On Deg ev Ka S f rd rd e 9 Oo o Whole House Power UTILITY When the customer decides that the generator SUPPLY should power the whole house just as if normal utility power is working the generator and ATS must be wired directly into the homes electrical distribution panel as shown Care must be taken when sizing the generator and ATS switch for each application refer to the specification sheets of the generator and automatic transfer switch to make sure the current and voltage ratings meet the energy needs of the installation Whole House Distribution Panel Typically when sizing a whole house system the generator current ratings should be equal to the main circuit breaker rating If not then the installer should calculate current draw of all electrical devices that may be on during an emergency power outage and size the generator accordingly Failure to do so will result in the generator being overloaded causing possible harm to the generator or electrical load System Concept Residential Power Systems Sizing
34. ctricity is present Open main circuit breakers of all power sources before servicing equipment Configure the installation to electrically ground the generator set and electrical circuits when in use Never contact electrical leads or appliances when standing in water or on wet ground as the chance of electrocution increases under such conditions High voltage test Hazardous voltage can cause severe injury or death Follow instruc tions of test equipment manufacturer when performing high voltage test on rotor or stator An improper test procedure can damage equip ment or lead to future generator set failures Installing battery charger Hazardous voltage can cause severe injury or death Electrical shock may occur if battery charger is not electri cally grounded Connect battery charger enclo sure to ground of a permanent wiring system As an alternative install an equipment ground ing conductor with circuit conductors and con nect to equipment grounding terminal or lead on battery charger Perform battery charger instal lation as prescribed in equipment manual Install battery charger in compliance with local codes and ordinances Connecting battery and battery charger Hazardous voltage can cause severe injury or death Reconnect battery correctly to avoid electrical shock and damage to battery charger and battery ies Have a qualified electrician install battery ies Safety Testing voltage regulator Hazardous voltag
35. d valve engines The generator set can utilize either LP or Natural Gas for the fuel supply The model designation corresponds with the full load kW rating of a 60 hertz unit operating on LP gas Due to the lower BTU rating of Natural gas approximately 12 less than the LP rating is normal when fueled by Natural gas Systems are available for both single phase 3 wire 120 240 volt 60 hertz and 110 220 volt 50 hertz applications Both voltage and frequency are field adjustable to closely match the utility supply gt E Generator Ratings Model Generator Standby Amps Standby Ratings kW kVA Series Voltage Phase Hz Model Natural Gas LP Gas Natural Gas LP Gas 8 5RES 120 240 1 60 2F4 29 35 7 0 7 0 8 5 8 5 8 5RES 115 230 1 50 2F4 27 33 6 3 6 3 7 5 7 5 12RES 120 240 1 60 2F4 43 50 10 4 10 4 12 0 12 0 12RES 115 230 1 50 2F4 40 46 9 3 9 3 10 5 10 5 RATINGS Standby ratings apply to installations served by a reliable utility source All single phase units are rated at 1 0 power factor The standby rating is applicable to variable loads with an average load factor of 80 for the duration of the power outage No overioad capacity is specified at this rating Ratings are in accordance with ISO 3046 1 BS5514 AS2789 and DIN 6271 GENERAL GUIDELINES FOR DERATING ALTITUDE Derate 4 per 305 m 1000 ft elevation above 153 m 500 ft TEMPERATURE Derate 1 5 par 5 5 C 10 F temperature increase above 16 C 60 F Availability is subject to c
36. e can cause severe injury or death High voltage is present at the voltage regulator heat sink Do not touch voltage regulator heat sink when testing voltage regulator or electrical shock will occur PowerBoost PowerBoost and PowerBoost V voltage regulator models only Engine block heater Hazardous voltage can cause severe injury or death Engine block heater can cause electrical shock Remove engine block heater plug from electrical outlet before working on block heater electrical con nections Electrical backfeed to utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause serious injury or death to utility personnel working on transmission lines 10 Fuel system Explosive fuel vapors can cause severe injury or death All fuels are highly explosive in a vapor state Use extreme care when handling and storing fuels Store fuel in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from spark Do not smoke or permit flame or spark to occur near sources of spilled fuel or fuel vapors Keep fuel lines and connections tight and in good condi tion Do not replace flexible fuel l
37. e crank with a reversed battery connection and system damage may occur The Starter Solenoid SS contains contacts that connect the battery to the starter brushes and a spring loaded drive mechanism which engages the starter motor pinion to the flywheel ring gear To insure a successful start up the battery must be properly maintained and kept fully charged STARTER ISOLENOID A I SS d i i Ir BATTERY ei ei i i i AS STARTER O MOTOR STARTER Starting System CUSTOMER Prono RMINALS REMOTE START S Sen e ENGINE START INTACTS ON TRANSFER H TT INSUL2 LI 4 P 1 26 REMOTE START STOP 2 Li od 3 e P 1 25 REMOTE START STOP 1 aad DAA P1 15 OIL PRESSURE SWTCH GOVERNOR i Sas ue an Se A BLK P1 17 VR SENSOR LOW el i P1 29 VR SENSOR HIGH QCON2 A BI P1 18 GROUND GOVERNOR 2 WHT A WHT Pi 8 COOLANT TEMP SENSOR HIGH EE P1 9 COOLANT TEMP SENSOR LOW EZ M S2 P1 21 GROUND AC SENSE AC SENSE 4 71 wire energized at crank only gt RELAY K1 35 Cyclic Cranking A cyclic cranking feature is provided which allows the starter to be energized for a preset time followed by a preset rest time This cycle will repeat until the total time allocated by the controller has lapsed or a successful start occurs Cranking time ON is factory set for 15 sec Rest period OFF is set for 15 sec This is a microprocessor based se
38. e load and alternator The toggles are tied together Moving the toggle will open or close both poles An over current fault exceeding the trip rating of the breaker will also trip both poles Current and trip ratings are located on the terminal side of the breaker ALTERNATOR LINE TERMINALS 8 5RES 40 amp breaker Ncusroen 12RES 50 amp breaker 54 Controller ounen 32018 MED gt YOLON YIAAILS MIS YOLWIS 1W1S JINGON MES LAWNS MdSS CIONTIOS BILIVIS SS AVIY NALYWLS YS YOLON YILVIS INS Han GINOYINOD NODMIS HDS OueOg JOVINGIN AWI3Y ald 193NNO2 WOIND NooD Dr Hd dd DUINOVN dp HOLIMS 3UNSSIYWA WO MOI d ONIS 07 X08 S3TIONINO9 01 JOYLNOD NOLLINO N QNNOYD XOA YIVOYINOD INO 3AWA TINA AS asna Ma YIONIS 3YNIVIIAMNAL LNVIOOD S19 30014 a yanvaus nu g5 blosen 193NNO2 LON OG LO3NNOD ON OU seg d 193NNO2 ION Od N OL S9 123NNOO SVS TVYNIVN au T 3SYHd TIONIS Zeg 33S SNOUIINNO9 YOLWSINIO NOS ALON AVI3O 938 0 0Q333SH3AD a SINI 938 01 gen Kate vee An 35035 OV ISI a W me ta Janne ov AYIZO JAS OL NWOQinHS 3OWINOALIONN EE ANO 935 Z NWOQInHS 39V110AN3AO 0328 IIVAA Y 19NNOOSIO We Owen 1210 MZ sio NMOGLNHS VR won BOSNIS MAL INVIOOD 6 10 mir RS a HOH YOSNIS dn INVIOOD U bd Iw D W SA annoys 811 ja 15 e HOU YOSNES
39. e unit is not operated with the filters removed Dirt particles entering the intake will cause premature engine wear and failure A clogged filter may cause excessive fuel consumption and a loss of engine power 25 Air Intake Fuel System Fuel System The generator set will operate on either Natural The fuel system employs the use of a fuel block or LP fuel in a gaseous state Manual shut off which allows either natural gas or LP fuels to be valves and Primary regulators are installed by used Fuel changeover is completed by the fuel supplier switching inlet ports and if necessary changing the ignition timing connection see ignition A secondary regulator and 12vdc solenoid valve systems are located in the front inlet air compartment The solenoid valve is energized from the The fuel block has adjustment for optimum controller to open at start and deenergize at engine performance on either NG or LP fuels shutdown A Y NPT inlet is provided The adjustments are set and sealed at the factory and should not be modified Inlet gas pressure to the regulator should not exceed 60z The regulator controls the pressure on engine demand A plug is provided at the regulator input for installation of a gauge or manometer if a pressure check is required A fuel lock off is also located in the regulator which prevents fuel flow when the engine is not operating This is adjusted at the factory and should not be used in an att
40. ed through an essential loads distribution panel which in turn is wired to the generator and ATS Sizing the generator for essential loads allows the customer to use a smaller generator to meet the homes electrical power needs during a power outage Essential Loads Panel 15 System Concept The majority of newer residential utility service entrances in the United States are protected by a 100 or 200 amp circuit breaker This main disconnect circuit breaker is generally located in a panel with the distribution circuit breakers The Normal 60 Hz voltage supply from the meter is usually single phase 3 wire 220 to 240 volts measured line to line and 110 to 120 volts line to neutral The neutral or common is tied to a ground lug When designing a Standby Power System the Emergency Generator set must match the voltage and frequency of the Normal source The Transfer switch must also have the same voltage and frequency rating of the Normal and Emergency power supplies for operation of the transfer mechanism System Concept If the total load of a 200 amp service is connected to the transfer switch the switch must meet or exceed the 200 amp rating even though the generator may only be capable of supplying 50 amperes UTILITY SUPPLY Whole House Distribution Panel The load applied to the generator can be reduced if required by manually opening distribution breakers Normally not all circuits are
41. ed to rectify the AC output voltage to a DC input voltage for rotor excitation PowerBoost Winding Gate Circuit A sensing circuit in the voltage regulator monitors the generator output voltage and gt provides a signal for controlled gating or Rotor Excitation E conduction of the SCR s The regulation circuit will provide a DC output to the rotor whenever the voltage monitored is A C Sine Wave below the nominal setting A voltage above the gt setting will turn the regulator DC output off The Diode Rectified regulator circuit is constantly turning on and off in pi A A A A its attempt to maintain its nominal setting SCR Rectified e _ _ BA Controlled Full 3 4 1 2 1 4 gt ON ON ON ON 44 Alternator Digital Voltage Regulator The rotor provides the magnetic field flux The DC supply required to produce the magnetic field is provided to the rotor from the PowerBoost exciter regulator Initial excitation at engine start up field flash is supplied to the rotor bush and slip ring assembly from the starting battery via relay contacts Flash Relay On sensing a successful engine start and alternator build up app 30 vac from Powerboost winding the battery supply is disconnected and excitation is provided from regulated rectified output from the SCR module to rotor via the FP FN leads and brushes The Digital Voltage Regulation circuit is packaged in the ADC con
42. empt to adjust fuel mixture or engine speed Factory sealed fuel adjustments Secondary regulator Fuel valve Fuel Lock Off 26 Natural Gas System The natural gas as supplied from the utility is in a vapor state The primary regulator for a natural gas system will be the responsibility of the utility that supplies the natural gas The heating value of Natural gas should be 1000BTU per cubic foot When heating content falls below 1000BTU the set will not produce rated power and will need to be derated Always check the specification sheet for the rating of the generator while running on natural gas many applications require derating of the full load power on natural gas When installing or troubleshooting the fuel system the following factors must be considered e Pressure loss due to length of pipe e Pressure loss due to other appliances on same fuel supply e Pressure loss due to number of fittings or elbows Measured pressure at the inlet to the secondary regulator should be 4 6 ounces per square inch or 7 11 inches water column The outlet or carburetor side of the secondary regulator should measure 4 5 inches water column under load Fuel System Boiling Point Initial End Btu s per Gallon Net LVH Gallon Gross Cubic Foot Gas Density Cubic feet of Gas per a Liquid per Gallon Li quid Octane Number Research Motor 27 LP Gas LP gas is supplied as
43. equipped with a factory installed battery charger The battery charger is powered by a 120vac source The 120vac source must be available when either utility or generator power is available The 6 amp charger has 3 modes of operation bulk rate absorption rate and float Bulk rate indicates the battery is discharged and the charger rate is 6 amps Absorption rate is when the charger is at a rate of 1 5 to 5 amps This mode of charging tops off the battery and reduces harmful sulfating Float rate is when the charger rate has dropped below 1 5 amps At 1 5 amps the battery is at 90 charge the charger rate will drop to 1 amps as the battery approaches 100 charge The charger will maintain this float rate without overcharging the battery The 6 amp charger has 2 LED s Red Green to indicate battery charger mode Bulk charge mode Red on Green off Absorption mode Red on Green on Float mode Red off Green on 37 Battery Charger LED indicating lights 10 amp fuse protection Scheduled Maintenance Procedure Visually Inspect Change Clean Test Frequency Quarterly Weekly Yearly See Section Flexible lines and connections Main tank supply level Fuel piping 8 hours or before use early or 500 hours early or 100 hours Oil level lt Crankcase breather Change oil Replace filter early or 200 hours Air ducts louvers Yearly a 7 Weekly Yearly Le
44. four cycle engines In recent years the com pany has also acquired two distinguished furniture manufacturers and opened a variety of highly successful hospitality businesses Headquartered in Kohler Wis Kohler Co is one of the oldest and largest privately held companies in the country and employs more than 20 000 people Power Systems Group Kohler Co a major producer of engines generators and electrical products entered the power systems market in the early 1900 s Its first power systems products included cast iron internal com bustion engines and Automatic Power and Light a remarkable improvement in auxiliary power in its day Generators then known as electrical plants supplied power during Admiral Richard Byrd s Antarctic exploration in the late 1920 s In the post war years Kohler expanded its engine and generator product lines and continued to improve the durability and performance of all of its power systems units Consequently the number of markets for Kohler power systems products grew throughout the United States and beyond Today Power Systems International created in 1989 and based in Kohler Wis is responsible for all Kohler generator and engine product sales outside of the United States Generator Division In use throughout the world Kohler generators are available for the marine home mobile commercial and industrial markets In addition to generator sets Kohler also manufactures transfer switches sw
45. g also has the FL output which controls the Field Flashing relay P 15 plug Relay Control Board K The ADC controller does not have relays mounted internally to the controller A relay board is required to interface controller logic to the generator start and stop functions Mounted on the relay board are 3 relays Crank Run and the Field Flash Relay There are LED s on the relay board that illuminate when the functioning relay is energized Crank Relay is energized when the control logic is in the crank mode Run Relay is energized when cranking or running Flash Relay is energized during crank and run and is disconnected when the aux winding output has reached 30 vac A 10 amp fuse powers the relay board and relay outputs contacts An optional relay board is available with an auxiliary run relay and common fault relay for customer connections 53 Controller Circuit protection The wiring harness has 3 in line fuses installed E ae ss pe CO Pod Ir F1 20 amp fuse protects the PowerBoost winding The Power Boost winding is respon sible for the excitation of the rotor PF2 P14 6 CH od yD 5 F2 10 amp fuse circuit protection for relay PF1 P1 24 q Ts po board fuel solenoid SR relay and ignition P module P jee F3 10 amp fuse circuit protection for the ADC controller The CIRCUIT BREAKER is a two pole device with trip elements in each pole and is used as a circuit disconnect between th
46. hange without notice Kohler Co reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever Contact your local Kohler Co generator distributor for availability Due to the cycling operation of many electrical appliances the generator set may not run all appliances simultaneously Check the appliance manufacturer s specifications for actual power requirements Consult a Kohler Power Systems professional for your exact residential power system requirements G4 97 8 5 12RES 1 04a 20 Alternator Specifications Compliance with NEMA IEEE and ANSI standards for temperature rise Self ventilation and drip proof construction Vacuum impregnated windings with fungus resistant epoxy varnish for dependability and long life Superior voltage waveform and minimum harmonic distortion from skewed alternator construction A rotating field alternator with static exciter for excellent load response 21 Specification Alternator Specification 8 5 12RES Frequency Hz 50 60 Phase Single Phase Number of leads 4 Excitation method Static Excited Voltage regulator type Digital Coupling type Direct Thrubolt torque Nm ft lb 40 28 Overbolt torque Nm in lb 7 60 Insulation rotor and stator Epoxy varnish vacuum impregnated Class 180 H Winding material Bearing number and type 1 replaceable ball Circuit protection
47. hru bolt If rotating crankshaft manually direction should be clock wise only Turning crankshaft bolt or rotor thru bolt counterclockwise can loosen hardware and result in serious personal injury from hardware or pulley flying off engine while unit is running Safety Gh d Fire Can cause severe injury or death Do not smoke or permit flame or spark to occur near fuel or fuel system A flash fire can cause severe injury or death Do not Smoke or permit flame or spark to occur near carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuel or fuel vapors When removing fuel line or carburetor use a proper container to catch all fuel A sudden backfire can cause severe Injury or death Do not operate with backfire flame arrestor removed gasoline models only A sudden backfire can cause severe Injury or death Do not operate with air cleaner silencer removed A sudden flash fire can cause severe Injury or death Do not smoke or permit flame or spark to occur near fuel system Keep the compartment and generator set clean and free of debris to minimize chances of fire Wipe up Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Grounding generator set Hazardous voltage can cause severe injury or death Electrocu tion is possible whenever ele
48. indings lamination slots and any conductive material used in the generator construction If this insulation deteriorates or breaks down a current path can be created between the copper windings and the frame structure This breakdown may not be detected when performing a continuity test Dirt grease chemical fumes aging and moisture are some of the contributing factors that can lead to the insulation breaking down A megger can be used to test for possible current leakage to ground that was not detected during continuity testing Meggers apply a voltage between the insulated conductor and the material they are insulated from usually ground They determine the resistance flow across the insulation of the conductor These resistance values are very high in the millions of ohms 1 Prior to operating a megger disconnect all stator leads 2 You can keep the load leads connected together but it is recommended that you disconnect all individual coils and test each one individually 3 The positive lead of the megger should be attached to the lead coil being tested on the alternator and the ground lead attached to the frame 4 Perform the megger test following the instrument instructions 5 As a general guideline if the insulation resis tance is greater then 1 5 megohms the insulation leakage is considered acceptable If it is below 1 5 megohms the stator needs to be serviced Always refer to instrument instruction or genera
49. ines with rigid lines Use flexible sections to avoid breakage caused by vibration Do not operate generator set in the presence of fuel leaks fuel accumula tion or sparks Repair systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is manda tory Propane is heavier than air install propane gas detectors low in room Inspect detectors often Natural Gas Adequate ventilation is mandatory Natural gas rises install natural gas detectors high in room Inspect detectors often Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check LP vapor gas or natural gas fuel system for leakage using a soap water solution with fuel system test pres surized to 6 8 ounces per square inch 10 14 inches water column Use a soap solution containing neither ammonia nor chlorine be cause both prevent bubble formation A suc cessful test depends on the ability of the solution to bubble Safety Explosion Gasoline vapors can cause explosion and severe injury or death Before starting generator set operate blower 4 minutes and check engine compartment tor gas oline vapors A WARNING Explosive fuel vapors Can cause severe Injury or death
50. ing Can cause severe injury or death Disconnect battery cables before working on generator set negative lead first and reconnect it last Accidental starting can cause severe Injury or death Disconnect battery cables remove negative lead first and reconnect it last to disable generator set before working on any equipment connected to generator Place controller MASTER switch to OFF position The generator set can be started by remote start stop switch unless this precaution is followed WARNING A Hazardous voltage Moving rotor Can cause severe injury or death Do not operate generator set without all guards and electrical enclosures in place Rotating parts Can cause severe Injury or death Do not operate generator set without all guards screens or covers in place Exposed moving parts can cause severe Injury or death Keep hands feet hair cloth ing and test leads away from belts and pulleys when unit is running Replace guards covers and screens before operating generator set Some scheduled maintenance procedures require the generator set to be running while performing service If the sound shield has been removed leaving belts and pulleys ex posed be especially careful of this area Flying projectiles can cause severe Injury or death Retorque all crankshaft and rotor hard ware after servicing When making adjustments or servicing generator set do not loosen crank shaft hardware or rotor t
51. itchgear and accessories for all product lines Kohler generators are produced in a manufacturing facility located in the town of Mosel eight miles north of Kohler Wis In 1997 Kohler opened and operates a manufacturing facility in Singapore for the international product line Engine Division One of the world s major manufacturers of air cooled four cycle engines Kohler Co produces models ranging from 4 horsepower single cylinder engines to 26 horsepower twin cylinder engines These engines are used by major manufacturers to power lawn and turf agricultural industrial construction and recreational equipment The Kohler engine is also used in Kohler generator models specifically the residential commercial product lines Kohler engines are manufactured in Kohler Wis and Hattiesburg Miss Kohler de Mexico S A de C V Created in 1964 and located in Mexico City Kohler de Mexico manufactures four cycle engines Safety Precautions and Instructions A generator set like any other electromechani cal device can pose potential dangers to life and limb if improperly maintained or imprudently operated The best way to prevent accidents is to be aware of the potential dangers and to always use good common sense In the interest of safety some general precautions relating to the operation of a generator set follow Keep these in mind This manual contains several types of safety precautions that are explained below DANGER D
52. k is controlled by the location of the flywheel magnet as referenced to the engine TDC and the delay created by the Spark advanced module Previous CH25 engines used a SAM or analog spark advance module this module has since been upgraded with a mocroprocessor controlled spark advance or DSAM K5 relay contact closes to ground at shutdown K5 relay contact 008 012 In 20 30 mm Air Gap Ignition System Ignition Timing There is an ignition timing connection located near the secondary gas regulator This connection needs to be made when using natural gas to run the 12RES generators This connection should be open when running LP with the 12RES The conection should be open on the 8 5RES when running either NG or LP Ignition Timing Connection 70A Energized when running Spark Advance Module Spark ignition Module 34 Starting System The generator set can be started locally by placing the start selector switch in the RUN position When placed in the AUTO position the generator set can be started from a remote location automatic transfer switch by contact closure between wires 3 amp 4 on the ADC controller A 10 amp fuse F2 protects the Crank Run circuit The electric starting system requires a 12 volt lead acid battery with a minimum 675 cold cranking amp rating The unit is designed for negative ground connections The controller will not allow an engin
53. l 6 3 0 of nominal 7 3 5 of nominal 8 4 0 of nominal 9 4 5 of nominal Nominal setting DELAY PL Le Active Diarra GENERATOR SRT 3P0X 64 Controller Governor Speed Coarse adjustment The course Speed adjustment is your first DUEPLAY RELAIS ACTAE setting When in the menu you will notice the o ti third digit flashing Adjusting the number up will raise the speed Adjusting down will lower the speed Before making any adjustments you should have a calibrated VOM measuring output Frequency Speed adjust range is 5 Fine Speed Adjustment when in the fine speed adjust mode the fourth digit will flash Press SELECT button to advance When in course Speed adjust the third to Governor Gain menu digit will flash When in fine adjust the fourth digit will flash 4PXX Governor Gain Adjust Gain adjustment may need to be done if the COSPLAY REL LINE LETVE DUI GEMLRATOR PLATO Engine responds slowly to load changes gain set to low or the engine has voltage instability or SPXX hunting gain set to high To set gain adjustments adjust the gain UP until the engine starts hunting similar to a dog barking then turn DOWN the gain setting until the engine becomes stable Cycle load on the generator output to make sure engine response is acceptable The final test would be to allow the When in course Governor Gain adjust generator to cool then start the generator this will the third digit wil
54. l flash When in fine verify that the engine does not respond to slowly adjust the fourth digit will flash causing the engine to overspeed EPA REN WA LETVE When speed gain is set press SELECT button ss de TANE until the SAVE menu is displayed press the UP button to save all settings Press the UP button to save settings 65 Upgrading ADC Software To upgrade the ADC 2100 requires 1 Program Loader version 2 3 or higher 2 Null modem cable 3 TT 1285 instructions for downloading software to ADC controller 4 ADC 2100 Application Program 5 Service Manual TT 6196 RES 6 Access to controller DB9 port RS 232 Once the ADC software has been upgraded the ADC controller will require configuration and adjustment of parameters specific to generator Distributors have access to Program Loader software and the ADC application software via the internet Controller Controller Replacement ADC has no replaceable assemblies Potting does not allow component changes Order kit GM33159 Includes TT 1364 for setup The ADC as a replacement controller requires that it be configured for the application It is not shipped from the factory ready for operation Programming systems menus will be required before the generator can be operated 66 Concept The Transfer Switch is a required component of an emergency or standby electrical power system It not only serves to transfer the load between electrical supplies bu
55. nance When performing inspection on brushes it is important to note the brushes are not sticking have good surface contact with the rings and the brushes are centered and riding completely on the rings Severe arching on the brushes may cause regulator to fail and also damage the slip rings Collector rings acquire a glossy brown finish in normal operation and cleaning to maintain a bright machined surface is unnecessary If grooves have developed on the collector rings a commuter stone should be used to level the surface Never use emery cloth or carborundum paper to level or clean collector rings 51 Alternator FP Remove Leads FP EN GA Remove Leads MEGGER STICKING POOR SURFACE NOT CENTERED CONTACT ON RING BRUSH CONTACT Controller ADC 2100 Controller The ADC 2100 is a microprocessor based controller The controller allows for manual and automatic operation The controller has built in diagnostics with the ability to display both generator warnings and shutdowns The controller keypad allows access to system configuration and voltage and frequency adjustment DE PEM THOR The LED display indicates generator fP Aayar Fait set status When operating normally j the generator total run hours will be ei displayed The LED display will also s LOS Loss ot Cece show active faults or warnings ge kJ Bret Framers a Seck S System Faults j a nae Ve Auxiliary F
56. nd time delay on engine start This feature prevents nuisance engine start attempts if only a momentary under 3 seconds loss of power occurs Ifthe Normal source returns prior to completion of the timing no engine start will be attempted and the timer will reset TDNE 2 second time delay on a Normal to Emergency transfer After a successful engine start a delay of 2 seconds is provided to allow the engine to attain operating speed and stabilize prior to applying load TDEN 12 second time delay on an Emergency to Normal transfer When Normal power returns to the Pick up voltage 190 vac a delay of 12 seconds will commence before allowing a transfer back to the Normal Source This is to allow the Utility power to stabilized If Normal power fails within this timing period timing will be terminated and reset TDEC 2 minute time delay for Engine cooldown On a successful retransfer back to the Utility the engine will operate for two minutes unloaded to allow a cooldown period prior to shutting down 72 Automatic Transfer Switch Circuit Board The main control board contains the intelligence logic as well as transformers relays jumpers and terminal strips Not all terminals and com ponents are used in this application TB1 JP2 TB2 NA LED EA LED et Ces EE Eer EES hees R20 EUV lt gt a pa a zl o 31 E gell R15 NUV 5VDC btu ste bts in Us ae wel o
57. ng for the voltage regulator circuit Leads 55 and ZER LO Ke N 66 provide the excitation power for voltage 2409 MM regulation L1 L2 120 v 3 Wire 110 v 3 Wire The Stator can be reconnected to a straight single voltage 2 wire or 3 wire configuration if required A jumper is placed on the line side of the circuit breaker to balance the load between the two windings 4 Lo Z Seng L1 41 Rotor The rotor is a powerful electromagnet which when rotating induces current flow in the stator windings The rotor windings field coils are energized by a DC supply from the Exciter Regulator via brushes and slip rings and magnetize the two laminated iron pole pieces The DC supply is increased or decreased depending on load demand applied to the generator and is automatically controlled or regulated by the voltage regulating portion of the ADC cortrioller logic The rotating speed of the rotor determines the frequency of the alternator output A two pole rotor must rotate at 3600 RPM to produce 60Hz 3000 RPM 50Hz The rotor which is directly coupled to the engine tapered stub shaft is supported by a bearing in the end bracket assembly 42 Alternator Field Excitation The rotor field windings are energized through field excitation Field excitation comes from a variable DC source called an exciter By varying the exciter voltage we can control the voltage and current induced into the ro
58. odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short period of time Carbon monoxide symptoms Carbon mon oxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas which is present in exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomach ache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible affected persons should seek fresh air immediately They should remain active They should not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning If the condition of affected persons does not improve within minutes of breathing fresh air they should seek medical attention Safety A caution Hazardous noise Can cause loss of hearing Never operate generator without a muffler or with faulty exhaust system Engine noise Hazardous noise can cause loss of hearing Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protec tion when near an operating generator set be A WARNING Accidental start
59. other jewelry before handling battery Never connect negative battery cable to positive connection terminal of starter solenoid Do not test battery condition by shorting terminals together or sparks could ignite battery gases or fuel vapors Any com partment containing batteries must be well ventilated to prevent accumulation of explosive gases To avoid sparks do not disturb battery charger connections while battery is being charged and always turn charger off before disconnecting battery connections When disconnecting battery remove negative lead first and reconnect it last Safety I V A Hot coolant and steam Can cause severe Injury or death Before removing pressure cap stop generator allow to cool and loosen pressure cap to relieve pressure Hot engine and exhaust system Can cause severe Injury or death Do not work on generator set until unit is allowed to cool Hot coolant can cause severe Injury or death Allow engine to cool and release pressure from cooling system before opening pressure cap To release pressure cover the pressure cap with a thick cloth then turn ft slowly coun terclockwise to the first stop After pressure has been completely released and the engine has cooled remove cap If generator set is equipped with a coolant recovery tank check coolant level in tank Hot parts can cause severe Injury or death Do not touch hot engine parts An engine gets hot while
60. pacitor to the primary of the T1 ignition coil This rapid flow of current in the primary induces a very high voltage in the T1 secondary windings sufficient to jump the spark plug gap and ignite the cylinder fuel mixture This firing occurs on every revolution of the flywheel Ignition is terminated by shorting the high side of the primary circuit to ground This is D1 ct accomplished by the K5 relay contacts Air gap between the core of the modules and the SCR magnet is 010 in 0 25mm TEE MAGNET This magneto type ignition requires no external P s battery supply or timing adjustments CAPACITIVE DISCHARGE IGNITION MODULE ignition Modules KN Jo ee K5 relay contact K5 contact closes Spark to ground at shutdown Plug 008 012 in 20 30 mm ie Gap Fiywhee 33 V SPARK A PLUG Ignition System CH740 The CH25 CH740 engine features a SMART SPARK or DSAM module mounted externally at the rear cylinder shroud Operation is similar to the capacitive discharge ignition except a spark advance circuit is provided to the triggering circuit and a battery voltage supply is required 70a The CH20 CD ignition module relies on the fixed timing circuit based on the L2 coil to trigger the SCR circuit The CH25 CH740 uses a microprocessor based circuit DSAM to trigger the SCR circuit This change allows for better engine timing in relation to fuels used The timing of spar
61. rn off an electric range element to run a toaster This practical home wattage requirement should be equal to or less than the kilowatt rating of your selected Kohler generator set 18 System Concept Total Watts Running Watts Starting Watts Required Typical Essential Loads u Air conditioner window 10 000 BTU Potter choices below Air conditioner central 20 000 BTU other choices below Electric range 6 in element Electric range 8 in element Freezer Furnace fan 3 4 HP Heat pump Light bulb 75 watts total wattage on bulbs Refrigerator treezer Security system Sump pump 1 3 HP Sump pump 3 4 HP TV Well pump ue HP Additional Perse Coffee maker Computer Dehumidifier Electric dryer Fan attic Fan ceiling Garage door opener 1 3 HP Iron Microwave oven Oven Radio Space heater Toaster Toaster oven Washing machine Water heater Air Conditioners E Air conditioner window 5 000 BTU Air conditioner window 18 000 BTU 1 5 ton Air conditioner window 24 000 BTU 2 ton Air conditioner central 10 000 BTU Air conditioner central 32 000 BTU 2 7 ton Air conditioner central 48 000 BTU 4 ton 19 FEATURES AND SPECIFICATIONS Models 8 5 and 12RES are powered by V Twin Kohler Command CH20 and CH740 air cooled overhea
62. running and exhaust system compo nents get extremely hot 12 Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix notice to gen erator set after reconnecting to a voltage different from the nameplate Order voltage reconnection decal 246242 from authorized service distributors dealers NOTICE Hardware damage Engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings American Standard hardware uses a series of markings and metric hardware uses a numeric system to indicate hardness Check markings on bolt head and nuts for identification NOTICE Canadian installations only For standby service connect output of generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 13 Safety System Concept UTILITY FACILITY UTILITY FACILITY System Concept The system concept features a utility primary source generator backup source and an automatic transfer switch connected to a building load The generator is designed to provide a dependable alternate source of electrical power When connected to an automatic transfer switch ATS the generator will be signaled to st
63. s 0 65 0 962 Air 1 00 0 775 Propane 1 50 0 633 Butane 2 10 0 535 29 Fuel System Maximum capacity of Pipe in Cubic Feet of gas per Hour for a Gas pressure of 0 5Psig or less Based on a 0 60 Specific Gravity Gas Nominal Length of Pipe Feet Size Diameter Inches Inches A pressure drop of 0 5 inch water column has been calculated into the chart to make allowances for a nominal number of fittings 30 Governor System The frequency of the alternator output is determined by the speed of the engine A 2 pole alternator must be driven at 3600 RPM to provide 60 hertz 3000 rpm 50 Hz The engine speed is maintained by an electronic governor system consisting of a magnetic pickup electric actuator and electronic control assembly The microprocessor based ADC controller maintains generator speed based on the mag pick up input The magnetic pick up which monitors the flywheel ring gear provides the speed reference signal to the ADC controller The ADC provides regulated power to the bi directional stepper motor actuator which is linked to the carburetor throttle arm Governor Failure or loss of the input speed signal from the pick up will result in a low or idle speed condition At cranking speed of a properly adjusted pick up should produce a minimum of 1 75vac Air gap is factory set at 0 040 in 1 02mm Engine speed is adjustable to 5 which allows a range of speed adjustment between 34
64. t also to prevent the sources from being connected together resulting in destruction of the system An Automatic Transfer Switch ATS consists of three major components 1 Stationary and movable heavy duty CONTACT ASSEMBLIES 2 An OPERATING MECHANISM for the moveable contacts 3 A CONTROLLER to monitor the system and provide signals for engine start and contact transfer The controller logic constantly monitors the condition of the utility or normal power supply A signal for an engine start will be give when the voltage or frequency is not at a predetermined level or fails completely When the Generator voltage and frequency are acceptable to the monitoring circuit the transfer operating mechanism will be ener gized causing a Load L transfer from the Normal N to the Emergency E source The controller will seek the primary source and on return of acceptable power will retransfer the load back to the normal source and initiate an engine shutdown Automatic Transfer Switch KOHLER POWER sy STE TRANSFER Sy de CONTROLLER CONTACT ASSEMBLY CONTROL LOGIC N CONTACTS UTILITY 67 Automatic Transfer Switch Contactor The 2 pole G220 Series contactor is available for 100 and 200 amp Standby Systems Generator O Emergency Connection This contactor is designed for use on line to line 220 240 volt single phase utility systems as provided to the majority of residences The
65. t voltage Adjusting down will lower the output voltage Before making any adjustments you should have a calibrated VOM measuring output voltage Each increment will change the output between 5 7 vac Press the SELECT button to advance to the fine voltage adjust Voltage Adjust fine when in the fine voltage adjust mode the fourth digit will flash In fine adjust each increment will change the output voltage between 5 and 7 volts Press SELECT button to advance to Regulator Gain menu Regulator Gain Gain adjustment may need to be done if the generator output voltage responds slowly to load changes gain set to low or the generator has voltage instability or light flicker gain set to high To set gain adjustments an analog meter should be used to monitor the output voltage Adjust the gain UP until the analog meter reading shows instability turn DOWN the gain setting until voltage becomes stable Cycle load on the generator output to make sure voltage response is acceptable SELECT both course and fine adjust the press SELECT to advance to Volts Hz Controller Dynamic adjustment menu s 1PXX Voltage adjust 2PXX Regulator gain Gain Adjust 3PXX Under frequency Voltage Droop Volts Hz 4PXX Governor speed adjust 5PXX Governor gain adjust GALA Rear ACTITE DWN GENERATOA CP are IPXX OMA When in course voltage adjust the third digit will flash When in fine adjust the fourth digit will flash
66. thin each menu The final menu will be SAVE To save all your settings press the UP arrow DSP A PER AS LETE GRIEG GENERATOR OPERATHON If you fail to save setting the configuration will revert back to original settings SAU E Once you have saved your settings the controller takes you out of the system configuration menus You will need to use the password to go back into the configuration menu Oe AN Press the UP button to save settings 60 Controller System Set Up Phase Frequency Voltage The first configuration code you dea s s want to select is for the system _ Settings _ _ phase voltage and frequency eg e le Phase 60 Hz 120 VAC Press the UP button to find the a ingle Phase 60 Hz 120 240 VAC _ correct code for your system anger EE Once this code is selected press E Single Ph Phase 50 Hz 230 30 VAC the SELECT button to advance to Three Phase 50 Hz 115 200 or 230 400 wc Hu _ Single Phase 50 Hz 1 EVERE _Uu06 Single Phase 50 Hz 115 230 VAC Application Next you need to select the generator application Uc00 Marine marine standby mobile Choose the correct Uc01 Standby code Press Select to advance to the next menu Uc02 Mobile Generator Model Choose the correct code for LED Display _ Ger gine Ty product lines advance more E EO SCH sm SC models are listed the software version will change to accommodate the new data in the software If yo
67. tor specification when determining when insulation leakage is suffcient to warrant repair or replacement 50 Alternator MEGGER Testing Rotor Brush Type Prior to testing the rotor inspect exposed coil windings brushes and collector ring surfaces Check rotor bearing for noisy operation excessive wear and heat discoloration Replace or repair if needed To check the rotor for continuity place the meter leads on the two collector rings Set meter to lowest setting for measuring resistance If a high resistance reading is found this indicates an open winding Typical measurement readings can be found in the specification section of the service manual for the particular rotor being tested To test for a grounded rotor place one meter lead to a collector ring and the other lead to the rotor shaft Meter should register no continuity Megger readings can also be taken by placing one lead of the megger to a collector ring and the other to the rotor shaft If reading is above 5 megohms the insulation leakage is acceptable If reading is below 5 megohms this indicates there may be current leakage to ground and servicing is needed The rotor may have moisture and needs to be dried out or the insulation is weak and the rotor will need to be serviced or replaced Note Make sure when taking resistance readings or performing a megger test that the brushes are not in contact with the slip rings Brush Collector Ring Mainte
68. tor thus controlling the voltage generated in the stator To control the exciter voltage a voltage regulator is incorporated into the alternator design and its selection is based on the type of excitation used on the alternator and the application of the generator Static Excited Brush Type This system rectifies AC power from the output of the generator and sends a controlled DC current to the rotating field through brushes collector rings This exciter is typically an SCR bridge controlled by a solid state voltage regulator circuit This system can be designed to have excellent load response and voltage regulation The disadvantages of static excited designs are found in the brushes and collector rings These components are subject to routine maintenance such as inspections of brush wear and buildup of dirt and carbon on the collector rings PowerBoost The Kohler version of static excited generators feature a patented PowerBoost exciter regulator It employs a separate auxiliary stator winding independent of the main output to power the field during fluctuations caused by load on load off situations This system provides excellent motor starting ability and maintains virtually constant voltage 43 BRUSHES SUP RINGS VOLTAGE REGULATOR SENSING BRUSHES SLIP RINGS Alternator MAIN GENERATOR FIELD Alternator SCR Rectification SCR s silicon controlled rectifiers are us
69. troller The SCR module is separate and is located at the rear of the stator The excitation component SCR rectifies AC from the auxiliary power coil 55 66 of the stator The voltage regulator circuit monitors the alternator AC output 11 44 and controls the firing Field drive of the SCR gate circuit providing regulated DC to the rotor slip rings The digital regulator provides 1 5 RMS Regulation Course and Fine Voltage adjustments can be made using the Dynamic settings in the ADC controller see controller dynamics settings The regulator can also be field adjusted for minimum voltage fluctuation and light flicker using the ADC dynamic settings see controller dynamic settings A Volts per Hertz feature automatically reduces the voltage if an overload causes the frequency to drop below a preset level factory set at 58hertz A 10 amp fuse F1 is provided to protect the power input circuit P16 3 AUX WINDING INPUT j 55 ORG 55 ORC 55 ORG FLASH SENSING ST x Field AC VOLTAGE REG L AUX WINDING INPUT 66 YtL Fs6 YEL 56 YEL P16 1 Flashing ac VOLTAGE FIELD DRIVE PLUS G BLK 9 DDR G BLK CONTROL P16 4 FIELD DRIVE MINUS L F RED m m F RED gece E FN l FN FP P15 1 AC SENSE 11 B8LU q 14 AC VOLTAGE REG ac SENSE 44 i 44 a P15 3 BRUSH HOLDER 45 46
70. tting and cannot be changed If the engine does not start within the total cyclic time the starting attempt will be terminated and an indication of overcrank OC will result The selector switch must be placed in the Reset Off position prior to attempting another start cycle Cyclic cranking provides the starting components a rest or reset period to prevent overheating and allows more efficient use of available battery power before it is depleted This is important especially for remote starting of an unattended unit STARTER RELAY OUT P1 1 COMMON FAULT OUT P1 3 FUEL RELAY OUT P1 13 P1 27 GROUND P1 24 VBAT FLASH RELAY OUT Starting System When a start signal is provided voltage is applied to the cyclic cranking circuit During the crank cycle the Start relay contacts will close energizing the cranking control relay SR When the SR contacts close the starter solenoid and Starter Motor will be energized If the engine starts within the cranking time of the cycle the Start relay will deenergize removing power from the coil of the SR relay and terminate engine cranking The Gas valve and Run relay will also be energized during the cranking cycle P14 6 VBAT IGNITION P14 4 P14 3 START RLY CONTROL P14 2 COM FLT RLY CONTROL P14 1 FUEL AUX RUN RLY CONTROL STARTER P14 9 P14 5 FLASH RLY CONTROL 36 6 Amp Battery charger The 8 5 and 12RES generator sets are
71. u are changing out a controller and the model is not found you will need to upgrade the software in the controller Press the SELECT button to advance to the next menu models will be listed When EO _ 10 24EOZD 920EFOZD eer 61 Adnc Advance Configuration The advance menu has three sub menus Engine Data Battery Voltage and Communication The advance menu is typically an area you will not have to go into unless you are make a generator modification in the field such as installing the remote gauge package for our marine product line To bypass this selection press SELECT to go to the SAVE menu Adnc Engine Data The engine data is automatically loaded into the system configuration when you choose the model number The only time you may have to modify the data selection is if an option sender device is added Press the SELECT button to advance to next Adnc sub menu Adnc Battery Voltage The battery voltage data is automatically loaded when you enter the model number code the default setting should be left as is Press SELECT button to advance to next sub menu Adnc Communications Communication setting will need to be changed if you add optional equipment which requires J1939 can communications This is not required for the 8 5 and 12RES product SAVE The SAVE menu is the final menu press the UP arrow to save all previous settings Controller Low Oil Low Low Mag LED Display Coolant
72. which relay 3 The Field flashing is required when 4 Fuse F1 protects the voltage regulator circuitry T or F 5 When is wire 70A energized 6 When is wire 71A energized 7 What is the purpose of the Magnetic Pickup 8 Which stator winding is responsible for excitation 9 What is the CTS 10 What symptoms will be observed if the Gas Valve coil electrically opens 11 What symptom will be seen if the Magnetic pick up loses output 12 What symptom will be seen if the F2 fuse opens 56 Controller lt YOLON Y3dd31S MiS BOIVIS 1W1S MOON AYVdS LYVNS AdSS QION310S Y31HVIS SS SJA MN ZL S8 ABONVIS oi 3313938 OIVIOHINOD NOOHIS YIS QuvO8 32V3H31NI AJY aly 1OaNNOD AINO NODD YOLDINNO9 fd ANd JLN dp HOJAS JUNSSIA NO MOT dO1 GMS 07 X08 Y3TIOHINO9 01 YOLOSNNOD ir OYINOD NOLLINO NO ONNOYI X08 YITIOYINO ONI 3AWA 134 Ad asha 3 GNNOYO 32018 INIONI 1 983 YIONIS JNNAVNIAMAL INYIOOO SID AND YiYvis YS 30010 j 0 YAON SUAVIS WS 89 YDVISO MDI HIHSYM Deitz MIOS ONE HATS ONISIXA JSA SION 993 LAA 08 Nu NO _NINO eg TS3NNOS LON OO ID3NNO2_10N 00 WEN S N z Dei Li If Nid NOLL IN Zay uos OW 99 9 S N s u5s aaa 4 1Ow 8985 080 ss s r u z zo u9s Ona a SNOMO3NNOS Std 405 da 82S Na us 583

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