Kohler Generator Loses Weekly Run Time

[Jeff95TA]

My parents have a Kohler 12RES with a controller that can be set to run the generator once a week for about 20 minutes. They've had a problem with it not starting when it should, so a technician came over and reset it (for $120). The next time it happened, I went and removed the front panel and pushed the button for 6 seconds myself to reset the timer.

It happened again this week after a loss of power. It seems that if it loses power, the controller loses the weekly run time and has to be reset. Does anyone know if that's what it's supposed to do, or if there's a problem with the unit?

I certainly don't mind going over to reset it for them, but it seems like this shouldn't be happening.

Thanks!

 

[mopho]

Should be a backup battery inside the panel. RTFM and see if it's user replaceable.

 

[Jeff95TA]

I don't see a battery backup, and there was no mention of one when I "RTFM".

 

[Bustawrench]

look on the control board for a backup battery.

 

[pattenp]

I believe the battery that starts the gen is the power supply for maintaining the timer.

 

[madosta]

Is there a battery maintainer on the generator (for the cranking battery)?

 

[Jeff95TA]

Is there a battery maintainer on the generator (for the cranking battery)?

If I understand your question correctly, part of the intent of the weekly 20 minute exercise is to keep the cranking battery charged.

I did call the local company that did the installation, and they said this is not normal for it to lose the memory.

 

[madosta]

If I understand your question correctly, part of the intent of the weekly 20 minute exercise is to keep the cranking battery charged.

I did call the local company that did the installation, and they said this is not normal for it to lose the memory.

Certainly, but cold temperatures are tough on batteries as well as the short charge cycle.

I only ask because I've seen weird electrical issues caused by a bad/dying battery only made worse by the cold weather. And maybe it tries starting, doesn't have enough battery to spin fast enough, drains the battery even more, causes the controller to lose voltage. I'm only guessing.

http://ths.gardenweb.com/forums/load/wiring/msg0614584922987.html

 

[Jeff95TA]

I see what you're saying. The generator did run last week during a power outage, so it looks like the battery is putting out enough to start it, but I'll check it to see if it might me going bad.

 

[SARG]

I keep a trickle charger hooked onto my generator battery 24/7.

 

[frankzlt1]

Im not too familiar with kohler generators but i do know generac generators and as for a generator stand point they cant be too different from each other, so what i think is there is something wrong with the control board. The timer is set if its by pushing a button in for a few seconds to set the controller remembers it from there now time is measured by Hertz if the power coming from street power the hertz slows down but the voltage is still in the right range the controller is good but the time will slow down same gos if the hertz speeds up a little. The generator needs to exercise once a week for lubercation of the seals in the motor amd most importantly for you to know the generator will run. There should be a battery charger built into the controller and depending on how the alternator is built some have 12v battery charge windings to charge the battery when the generator is running. The newer generators dont have those windings anymore and the battery charger is wired off the load side of the transfer switch and feed with 120v primary. Also if you put a trickel charger on you have a good chance on burning up your control board because its only designed to take about 13v dc or little more for only a short time.

 

[mark02184]

Jeff, my folks also have a Kohler 12RES along with a RDT100 amp transfer switch. As soon as they lose power, the exerciser timer loses its memory. The generator starts fine, etc. when the power goes off, but whether a 20 second "blink" where the generator pops on for just a few minutes--to a multiple day power loss event, that exerciser timer has to be reset.

The unit is 7 years old. So, I decided to replace the 12v starter battery, which I did. timer problem still exists. While replacing the battery, I kept it disconnected for over 20 minutes--a true "power recycle" since I believe the battery powers the board that controls the timer.

I removed the cover of the transfer switch and located the controller circuit board. I could not find any type of button battery that might keep the timer alive during a power outage. I'll bet if such a feature exists, it is capacitor driven.

The only think I can think at this point is to describe what I have discovered to a good Kohler tech, and I'm sure he'll recommend the transfer switch board be replaced. For some reason, I just think that will be expensive! But I'm getting tired of having my 85 year old Dad reset the timer all the time....at least the switch is inside a warm basement!

 

[Jeff95TA]

Yeah, I need to get the tech back out there. Could be a bad capacitor if that is indeed what keeps the memory. I want to be there this time when they come since they charged my parents the first time and didn't fix the problem. I'm going to specifically ask them if the exercise time is stored in non-volatile memory, or if it requires a power source to retain it, and if so what that power source is.

Thanks for your input Mark! I'll let you know what I find out.

 

[cowboyjosh]

Sounds like a Control board. It's a Common failure on the 12RES series. Kohler don't sell parts to the public over the phone or online; so find a distributor who might, or for the money, call and pay for a diagnosis and repair. Problems aside, I do like my KOHLER generators, in fact my 50 KW unit for my house gets serviced on Wednesday!

 

[mark02184]

Thanks, Jeff. Definitely want to hear your outcome. My folks are on Cape Cod, and their generator has been getting a workout quite regularly this winter with a ferocious wind storm a few weeks ago (power out for 3 days) and last week's blizzard (power out for 2 days), so since it IS coming on as needed automatically and running like a champ, I'm leaning toward picking up the exercise issue in the Spring!!

Cowboy, I've heard this is a common problem on the 12RES as well, so I'll TRY to get a freebie from Kohler, but I'm sure I won't have much luck as its going on 7 years old...but you never know. 50 KW??!!! Wow, you powering 1/2 the town or what!!??