Kohler 10RESV generator for battery backup on stand alone system.

metalguy21 · January 2

I have been having issues with the gas powered Bobcat 250 welder/generator generator I originally installed on my system. It was never wired quite right (blows fuses on each start) and in any case is gasoline powered so must be manual start. I think a Kohler 10RESV could be a possible replacement. I believe it is native two wire auto-start and compatible with my current Conext AGS. Anyone with any experience with this setup? How hard is this to get working.

JRHill · January 4

Detail your process for starting the Miller Bobcat for charging the batteries.

I have a 225 in the shop on a transfer switch to the house. It is the backup to the 4.6kw genset used every day of the winter. The Bobcat works wonderfully for a welder or a 240vac load but as a charger for batteries it is terribly inefficient. I have never popped a breaker on anything in 15 years.

metalguy21 · January 6

The Bobcat welder/Gen is hooked up to a Conext AGS unit that is networked to a XW6048 Power Center. This allows various hardware variations to the Conext while the XW system control panel can make all the configurations settings and allows manual control over Gen Start/Stop/Run. The Bobcat is wired up to use it's #45 Start wire with the Conext Relay #2 and it's white Start signal #17 wire that triggers when you hit manual start. It uses the Bobcats #41 wire with the Conext blue #14 run wire to run. To stop the Bobcat #46 to the battery is connected through Relay #1 to the Conext #6 and #8 wires that will trigger a stop by either manual input or configured timeout. Generally this is the Type 8 setup on the Conext box.

When starting manually you can here some sort of relay in the Bobcat click and then nothing. Looking at the fuse in the Conext start wires the fuse blows. Typically replacing the fuse solves this and it will start. So the question is why this blowing the fuse all the time. And it's not all the time, just every other time. Same happens when the Conext reaches its max run setting (4 hours in my case) and shuts down automatically.

As you can see this had nothing, as far as I can see, in common with a simple transfer switch situation. But maybe someone can untangle this mess. Note that I did not wire it this way, the people who installed my system did.

JRHill · January 6

You have not mentioned that the Bobcat was last left set with the voltage and amp dials at max which is necessary for it to operate as a generator at 120/240. If either dial is less than max it will affect system AC connect voltage and AC generator operation. You would know if you checked with a voltmeter before connecting. Your system should give a low AC input error.

With my Outback stuff the Bobcat will not connect if the dials are not at max because I have the acceptable AC input voltages tight - like 110 to 135vac. Or the equivalent through the auto transformer.

It's a wonderful off grid welder and for an A/C power plant is first rate. That's why you see so many of these blue boxes on the back of service trucks.

Dave Angelini · 12:16AM

At the bar talk... XW is much more finicky with input voltage quality/levels than an outback VFXR3648.
Kind of apples and oranges.

Kohler 10RESV generator for battery backup on stand alone system.

Comments

Categories