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Instruction Manual for KOHLER models including: 14RCA Aluminum Home Standby Generator, 14RCA, Aluminum Home Standby Generator, Home Standby Generator, Standby Generator, Generator
Kohler 20kW Aluminum Home Standby Generator | Kohler 20RCA
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DocumentDocumentOperation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL 26RCA 26RCAL Controller: RDC2 TP-7092 9/23e WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factoryauthorized dealers install and service the generator. Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits. Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate(s). Model Designation _________________________________________________________ Specification Number _______________________________________________________ Serial Number: ____________________________________________________________ Controller Identification Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Controller Description________________________________________________________ Engine Identification Record the product identification information from the engine nameplate. Manufacturer_________________________________________________________________ Model Designation___________________________________________________________ Serial Number_______________________________________________________________ Accessory Number Accessory Description Accessory Number Accessory Description 2 TP-7092 9/23 Table of Contents Safety Precautions and Instructions ........................................................................................................................................ 7 Introduction .............................................................................................................................................................................. 13 Service Assistance................................................................................................................................................................... 16 Section 1. Descriptions and Service Views ........................................................................................................... 17 1.1 Introduction ............................................................................................................................................................ 17 1.2 Engine .................................................................................................................................................................... 17 1.3 Alternator................................................................................................................................................................17 1.4 Generator Set Enclosure ........................................................................................................................................ 17 1.5 Transfer Switch ...................................................................................................................................................... 17 1.6 Controller................................................................................................................................................................18 1.7 OnCue® Plus Generator Management System ..................................................................................................... 20 1.8 Accessories ............................................................................................................................................................ 20 1.8.1 Cold Weather Package Kit ....................................................................................................................... 20 1.8.2 Battery Heater Kit.....................................................................................................................................21 1.8.3 Breather Tube Heater and Oil Heater Kit ................................................................................................. 22 1.8.4 Fuel Regulator Heater (20 and 26 kW models only) ................................................................................ 23 1.8.5 Oil Pressure Sensor Boot Kit ................................................................................................................... 24 1.8.6 Carburetor Heater .................................................................................................................................... 24 1.8.7 Emergency Stop Kit ................................................................................................................................. 25 1.8.8 Load Management ................................................................................................................................... 25 1.8.9 PowerSync Automatic Paralleling Module (APM) .................................................................................... 26 1.8.10 Programmable Interface Module (PIM) .................................................................................................... 26 1.9 Service Views.........................................................................................................................................................27 Section 2. Generator Set Operation ....................................................................................................................... 29 2.1 Prestart Checklist ................................................................................................................................................... 29 2.2 Exercising the Generator Set ................................................................................................................................. 29 2.3 Generator Set Operation ........................................................................................................................................ 29 2.3.1 Local Starting and Stopping ..................................................................................................................... 30 2.3.2 Automatic Operation ................................................................................................................................ 30 2.3.3 Remote Starting and Stopping ................................................................................................................. 30 2.3.4 Remote Emergency Stop Switch ............................................................................................................. 30 2.3.5 Engine Start Crank Cycle.........................................................................................................................32 2.3.6 Engine Cooldown ..................................................................................................................................... 32 2.3.7 Automatic Operation with Model RXT Transfer Switch ............................................................................ 32 2.3.8 Automatic Operation with Other Transfer Switches ................................................................................. 32 2.4 Exercise ................................................................................................................................................................. 33 2.4.1 Setting the Exerciser ................................................................................................................................ 33 2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics ................................................................. 33 2.4.3 EcoExercise (26RCA/L only)....................................................................................................................34 2.4.4 Unloaded Full-Speed Exercise.................................................................................................................34 2.4.5 Loaded Full-Speed Exercise (with RXT only)...........................................................................................34 2.4.6 Shutdown During Exercise (Advanced Diagnostic) .................................................................................. 35 2.4.7 Power Failure During Exercise Cycle.......................................................................................................35 2.5 Faults ..................................................................................................................................................................... 35 2.5.1 Warnings..................................................................................................................................................35 2.5.2 Shutdowns ............................................................................................................................................... 35 2.5.3 Shutdown During Exercise (Advanced Diagnostic) .................................................................................. 35 2.5.4 ATS Communication Errors ..................................................................................................................... 35 TP-7092 9/23 3 2.5.5 Resetting the Controller After a Fault Shutdown ...................................................................................... 36 2.5.6 Faults Related to Paralleling .................................................................................................................... 39 Section 3. RDC2 Controller Operation ................................................................................................................... 41 3.1 RDC2 Generator Set/Transfer Switch Controller....................................................................................................41 3.2 Control and Indicators ............................................................................................................................................ 41 3.2.1 Controller Keypad .................................................................................................................................... 42 3.2.2 LED Indicators ......................................................................................................................................... 43 3.2.3 LCD Display ............................................................................................................................................. 43 3.3 Controller Power .................................................................................................................................................... 44 3.4 Battery Charging .................................................................................................................................................... 44 3.5 Changing Settings .................................................................................................................................................. 45 3.6 Setting the Exerciser .............................................................................................................................................. 47 3.6.1 Setting the Exerciser at Controller Power-up ........................................................................................... 47 3.6.2 Changing the Exercise Settings ............................................................................................................... 47 3.7 RDC2 Controller Menus ......................................................................................................................................... 49 3.8 Main Menu ............................................................................................................................................................. 49 3.9 Overview Menu ...................................................................................................................................................... 50 3.10 Engine Metering Menu ........................................................................................................................................... 51 3.11 Generator Metering Menu ...................................................................................................................................... 52 3.12 Generator Set Information Menu ............................................................................................................................ 53 3.13 Genset Run Time Menu ......................................................................................................................................... 53 3.14 Genset System Menu.............................................................................................................................................54 3.15 ATS Status Menu ................................................................................................................................................... 56 3.16 ATS Configuration Menu ........................................................................................................................................ 57 3.17 Date and Time Menu..............................................................................................................................................58 3.18 Networking Information Menus...............................................................................................................................58 3.18.1 Networking Status Submenu....................................................................................................................59 3.18.2 Networking Configuration Submenu (OnCue® Password) ...................................................................... 60 3.18.3 RBUS Information .................................................................................................................................... 62 3.18.4 Remote Devices Submenu ...................................................................................................................... 63 3.19 Programmable Interface Module (PIM) Status Menu ............................................................................................. 64 3.20 Load Control Menus ............................................................................................................................................... 65 3.21 Event Log ............................................................................................................................................................... 66 Section 4. Scheduled Maintenance ........................................................................................................................ 67 4.1 Scheduled Maintenance ......................................................................................................................................... 67 4.1.1 Service Schedule, 14 kW Models ............................................................................................................ 68 4.1.2 Service Schedule, 20 and 26 kW Models ................................................................................................ 69 4.2 Lubrication System.................................................................................................................................................70 4.2.1 Low Oil Pressure Shutdown.....................................................................................................................70 4.2.2 Low Oil Level Switch (26RCA) ................................................................................................................. 70 4.2.3 Oil Check ................................................................................................................................................. 70 4.2.4 Engine Oil Recommendation ................................................................................................................... 71 4.2.5 Oil Change Procedure ............................................................................................................................. 71 4.2.6 Resetting the Maintenance Timer ............................................................................................................ 72 4.2.7 Oil Cooler (20RCA/L and 26RCA/L only) ................................................................................................. 73 4.3 Spark Plugs ............................................................................................................................................................ 73 4.4 Air Cleaner Service ................................................................................................................................................ 75 4.4.1 Air Cleaner, 14 kW Models ...................................................................................................................... 75 4.4.2 Air Cleaner, 20/26 kW Models ................................................................................................................. 76 4.5 Cooling System ...................................................................................................................................................... 77 4.6 Exhaust System ..................................................................................................................................................... 77 4 TP-7092 9/23 4.7 Battery....................................................................................................................................................................77 4.7.1 Cleaning the battery ................................................................................................................................. 78 4.7.2 Checking Electrolyte Level.......................................................................................................................78 4.7.3 Checking Specific Gravity ........................................................................................................................ 79 4.8 Storage Procedure ................................................................................................................................................. 80 4.8.1 Lubricating System .................................................................................................................................. 80 4.8.2 Fuel System ............................................................................................................................................. 80 4.8.3 Cylinder Lubrication ................................................................................................................................. 80 4.8.4 Exterior Preparation ................................................................................................................................. 80 4.8.5 Battery ..................................................................................................................................................... 80 Section 5. Troubleshooting..................................................................................................................................... 81 5.1 Introduction ............................................................................................................................................................ 81 5.2 Fault Messages ...................................................................................................................................................... 81 5.3 Circuit Protection .................................................................................................................................................... 81 5.3.1 Controller Internal Circuit Protection ........................................................................................................ 81 5.3.2 Line Circuit Breaker ................................................................................................................................. 81 5.4 USB Port and Auxiliary Winding Mini-Breaker........................................................................................................82 5.5 Stop Switches ........................................................................................................................................................ 82 5.6 Thermostat ............................................................................................................................................................. 82 5.7 Troubleshooting ..................................................................................................................................................... 84 Appendix A. Abbreviations ......................................................................................................................................... 85 TP-7092 9/23 5 6 TP-7092 9/23 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to physical injury. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals. Accidental Starting WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative () lead first. Reconnect the negative () lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. TP-7092 9/23 7 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Never connect the negative () battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. 8 TP-7092 9/23 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building's occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer's instructions. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: · Light-headedness, dizziness · Physical fatigue, weakness in joints and muscles · Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision · Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. TP-7092 9/23 9 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels 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 sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch (1014 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. Hazardous Noise CAUTION Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Engine noise. Hazardous noise can cause hearing loss. 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 protection when near an operating generator set. 10 TP-7092 9/23 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage. Backfeed to the utility system. Can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. CAUTION Welding the generator set. Can cause severe electrical equipment damage. Welding on generator set will cause serious damage to engine electronic controls components. Disconnect all engine electronic control connections before welding. Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative () lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery-charging alternator connections. (5) Attach the weld ground connection close to the weld location. Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. TP-7092 9/23 11 Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts. NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. 12 TP-7092 9/23 Introduction This manual provides operation and maintenance instructions for Residential/Commercial Model 14RCA/RCAL, 20RCA/RCAL, and 26RCA/RCAL generator sets equipped with the RDC2 generator set/transfer switch controller. See Figure 1. RCAL models are shipped with a Kohler model RXT Automatic Transfer Switch (ATS). The ATS Operation/Installation Manuals are included with the transfer switch. Kohler strongly recommends that only factory authorized dealers install and service the generator. Have the generator set installed outdoors by an authorized dealer or service technician. Refer to the Installation Manual for installation instructions. Do not install or operate the generator set indoors. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference. The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Obtain service from an authorized service dealer to keep equipment in top condition. Figure 1 Generator Set aac11780 TP-7092 9/23 13 List of Related Literature Figure 2 identifies literature available for the generator sets and related accessories covered in this manual. Only trained and qualified personnel should install or service the generator set. Generator Set Literature Specification Sheet, 14RCA/L Specification Sheet, 20RCA/L Specification Sheet, 26RCA/L Installation Manual, Generator Set Operation Manual, Generator Sets Warranty Registration and Controller Unlock Code Service Manual, Generator Set Transfer Switch Literature Operation/Installation Manual, Model RDT Transfer Switch Operation/Installation Manual, Model RXT Automatic Transfer Switch Accessory Literature User Guide, OnCue© Plus Technical Manual, OnCue© Plus Operation Manual, SiteTechTM Software Firmware Update Using the USB Utility Accessory Installation Instructions Carburetor Heater Kit, 14 kW Models Carburetor Heater Kit, 20 and 26 kW Models Fuel Regulator Heater Kit Programmable Interface Module (PIM) PowerSync® Automatic Paralleling Module (APM) Load Shed Kit Battery Heater Kit Power Relay Modules Breather Tube Heater and Oil Heater Oil Pressure Sensor Boot Kit OnCue Plus Wireless Kit Remote Emergency Stop Switch (Lockable) Figure 2 Related Literature Literature Part No. G4-270 G4-272 G4-315 TP-7091 TP-7092 TP-7238 TP-7093 TP-7192 TP-7193 TP-7006 TP-7007 TP-6701 TT-1636 TT-1297 TT-1482 TT-1569 TT-1584 TT-1596 TT-1609 TT-1634 TT-1646 TT-1709 TT-1717 TT-1721 TT-1795 14 TP-7092 9/23 Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See the service views section for the nameplate location. Genset Model Spec Number Serial Number Material Number Service Duty Amps kW Voltage Phase kVA Alt Model RPM PF Insulation Battery Hz MFG Date Fuel Figure 3 Typical Nameplate GM12070 Emission Information The Kohler® Model CH740 engine used on the 14RCA/L generator set is certified to operate using natural gas or propane fuel. The Kohler® Model CH1000 engine used on the 20RCA/L and 26RCA/L generator sets is certified to operate using natural gas or propane fuel for emergency standby use only. This generator set is certified by the U.S.EPA for emergency standby operation backing up a reliable utility source. Operation outside these guidelines is a violation of national EPA regulations. The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements. Figure 4 provides the engine compliance period (in hours) associated with the category descriptor, which may be found on the certification label. EPA CARB Figure 4 Emission Compliance Period Category C Category B 250 hours 500 hours Moderate Intermediate 125 hours 250 hours Emission Compliance Period Category A 1000 hours Extended 500 hours Refer to the certification label for engine displacement. The exhaust emission control system for the CH740 engines (14RCA/L) is EM for U.S. EPA, California, and Europe. The exhaust emission control system for the CH1000 engine (20RCA/L and 26RCA/L) is EM for U.S. EPA, California, and Europe. TP-7092 9/23 15 Generator Set Application Kohler® Co. ensures that all Kohler® generator sets are certified to applicable standards for their intended application. It is the owner/operator's responsibility to operate Kohler® generator sets exclusively according to the directions provided in the accompanying operation manuals. Kohler® generator sets designated as Stationary Standby, Emergency or Emergency Standby may only be operated for emergency power generation and for maintenance/testing. Emergency power generation is limited to power production when electric power from a local utility (or the normal power source, if the facility runs on its own power production) is interrupted. Stationary non-emergency application of a Standby, Emergency, or Emergency Standby rated generator set is not allowed. The U.S. Clean Air Act explicitly prohibits using Emergency Standby generator sets as a primary electric power source regardless of whether a site is connected to the electrical grid. Emergency Standby generators may NOT be used to power sites which are not connected to an electric utility. Owners/operators must ensure that the generator is operated, exercised, and maintained according to this operation manual. Owners/operators must retain maintenance records. Service Assistance For professional advice and conscientious service, please contact your nearest Kohler dealer. · Visit the Kohler Co. website at KOHLERPower.com. · Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. · Call toll free in the US and Canada 1-800-544-2444. 16 TP-7092 9/23 Section 1. Descriptions and Service Views 1.1 Introduction The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local dealer. 1.2 Engine The generator set has a four-cycle, twin cylinder, air-cooled Kohler® engine. The engine operates on clean-burning natural gas or LPG. Engine features include: · Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliability under all operating conditions. · Dependable, maintenance-free electronic ignition. · Precision-formulated cast iron construction of parts subjected to the most wear and tear. · Field-convertible multi-fuel systems that allow fuel changeover from natural gas to LPG (and vice-versa) while maintaining emission certification. · Digital spark advance optimizes ignition timing for the selected fuel. 1.3 Alternator The generator uses Kohler's unique PowerBoostTM voltage regulation system, which provides instant response to load changes. PowerBoostTM ensures reliable motor starting and consistent voltage levels. PowerBoostTM utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage. 1.4 Generator Set Enclosure The generator set is housed in an aluminum enclosure with our fade-, scratch-, and corrosion-resistant Kohler® Power ArmorTM automotive-grade textured cashmere finish. The enclosure has a hinged, locking roof that allows easy access to the generator set controller when required, but locks securely to prevent unauthorized access. To open the roof, insert the key provided with the enclosure and turn counterclockwise ¼ turn. Then just raise the roof. The roof stays open until you are ready to close it. Be sure to close and lock the enclosure, and keep the key in a secure location. 1.5 Transfer Switch The RDC2 controller is designed to interface with and control the Kohler Model RXT Automatic Transfer Switch (ATS). If the power system uses a different model transfer switch, the RDC2 controller will not control the transfer switch. An ATS other than the Model RXT must be equipped with a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set. TP-7092 9/23 17 1.6 Controller RCA and RCAL models are equipped with the RDC2 controller. See Figure 5. The controller provides integrated control for the generator set, Kohler® Model RXT transfer switch, programmable interface module (PIM) and load management devices. The controller's 2-line LCD screen displays status messages and system settings that are clear and easy to read, even in direct sunlight or low light. Figure 5 RDC2 Generator Set Controller RDC2 Controller Features · Six-button keypad o OFF, AUTO, and RUN pushbuttons o Select and arrow buttons for access to system configuration and adjustment menus · LED indicators for OFF, AUTO, and RUN modes · LED indicators for utility power and generator set source availability and ATS position (Model RXT transfer switch required) · LCD display o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility in all lighting conditions · Scrolling system status display o Generator set status o Voltage and frequency o Engine lube oil temperature o Oil pressure o Battery voltage o Engine runtime hours · Date and time displays · Smart engine cooldown senses engine temperature · Digital isochronous governor to maintain steady-state speed at all loads 18 TP-7092 9/23 · Digital voltage regulation: ±0.5% RMS no-load to full-load · Automatic start with programmed cranking cycle · Programmable exerciser can be set to start automatically on any future day and time, and run every week or every two weeks · Exercise modes o Unloaded cycle exercise with complete system diagnostics o Unloaded full-speed exercise o Loaded full-speed exercise (Model RXT ATS required) · Front-access mini USB connector for Kohler® SiteTechTM connection · Integral Ethernet connector for Kohler® OnCue® Plus Generator Management System · Built-in battery charger · Remote two-wire start/stop capability for connection of Model RDT or other transfer switches · Diagnostic messages o Displays diagnostic messages for the engine, generator, Model RXT transfer switch, programmable interface module (PIM), and load management device o Over 70 diagnostic messages can be displayed · Maintenance reminders · System settings o System voltage, frequency, and phase o Voltage adjustment o Measurement system, English or metric · ATS status (Model RXT ATS required) o Source availability o ATS position (normal/utility or emergency/generator) o Source voltage and frequency · ATS control (Model RXT ATS required) o Source voltage and frequency settings o Engine start time delay o Transfer time delays o Voltage calibration o Fixed pickup and dropout settings · Programmable Interface Module (PIM) status displays o Input status (active/inactive) o Output status (active/inactive) · Load control menus o Load status o Test function TP-7092 9/23 19 1.7 OnCue® Plus Generator Management System The Kohler® OnCue® Plus Generator Management System is now included with the generator set. The OnCue® Plus System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device. OnCue® Plus can be configured to send email or text message notifications in the event of a generator set fault. You can also use Google Assistant or Amazon Alexa and your smart device to control your generator. Use voice commands to check your generator's status, check for active alerts, and start or stop an exercise. See the OnCue® Plus User Guide, TP-7006, for simple setup instructions and voice commands. OnCue® Plus Wireless is also available. OnCue® Plus Wireless works with the customer's wireless Ethernet router and does not require the installation of a network cable between the generator set and the customer's router/modem. 1.8 Accessories The following optional accessories are offered for the generator sets. 1.8.1 Cold Weather Package Kit Heater kits are recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). The cold weather package kit includes: · Alternator brush cover · Battery heater · Breather tube heater · Fuel regulator heater · Oil heater · Oil pressure sensor cover · 3-way extension cord for power connection The heaters require a continuous source of AC power. See the generator set Installation Manual and the installation instructions provided with the kits for more information. 20 TP-7092 9/23 1.8.2 Battery Heater Kit The battery heater kit contains a heating wrap to help warm the battery in cold climates. See Figure 6. The battery heater is equipped with a thermostat that turns the heater on at 16-18°C (60-65°F) and off at 27°C (80°F). Battery heaters are recommended for regions where the temperature regularly falls below 0°C (32°F). Note: Battery heaters are compatible with all Kohler-supplied lead-acid batteries. For other battery types, check the battery manufacturer's instructions for any restrictions regarding the use of battery heaters. The battery heater requires a source of AC power. Verify that AC power is connected to the generator set as described in the generator set Installation Manual. The circuit must be backed up by the generator set to provide power at all times. Power cord for 120 volt kits Battery heater wrap Power cord for 240 volt kits Power cord Retaining strap or cable ties (included) Figure 6 Battery Heater (typical) TP-7092 9/23 21 1.8.3 Breather Tube Heater and Oil Heater Kit The breather tube heater and oil heater kit is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). Note: The heaters require a continuous source of AC power. See Figure 7 and Figure 8 for the power supply voltage required. Note: The breather tube heater and oil heater must be used together. Verify that AC power is connected to the generator set as described in the generator set Installation Manual. The circuit must be backed up by the generator set to provide power at all times. Refer to TT-1709 for instructions to install the heaters and connect 120VAC power. See Figure 9 and Figure 10 for illustrations of the 120VAC breather tube heater and oil heater. Heater Part Number GM110893, GM110894, and GM118784 Voltage Thermostat ON Thermostat OFF 120 VAC 4°C (40°F) 13°C (55°F) Figure 7 Breather Tube Heater Specifications Heater Part Number Voltage Thermostat ON GM110895, GM110896, and GM118784 120 VAC 4°C (40°F) Thermostat OFF 13°C (55°F) Figure 8 Oil Heater Specifications Heating element 120 VAC female connector (connect to oil heater) Thermostat Label 120 VAC plug Figure 9 Breather Tube Heater Heating element Heating probe Figure 10 Oil Heater Thermostat Label 120 VAC male connector (connect to breather tube heater) GM101483 22 TP-7092 9/23 1.8.4 Fuel Regulator Heater (20 and 26 kW models only) An optional fuel regulator heater is recommended for models 20RCA/L and 26RCA/L for improved cold starting in locations where the ambient temperature drops below -18°C (0°F). The heater requires a continuous source of AC power. Heater rating Thermostat Pad diameter Cord length 120 VAC, 60 W 240 VAC, 100 W 4°C/13°C (40°F/55°F) Snap action 127 mm (5 in.) 914 mm (36 in.) Figure 11 Regulator Heater Kit Specifications 20 kW Model Figure 12 Fuel Regulator Heater Pad 26 kW Model Bushing Cable ties Screw, spacer, and existing nut Heater, fuel regulator pad Note: Place spacer between regulator and mounting bracket Figure 13 Fuel Regulator Heater Installation, 20RCA/L and 26RCA/L TP-7092 9/23 GM79142 Cable ties GM79141H 23 1.8.5 Oil Pressure Sensor Boot Kit The oil pressure sensor boot protects the oil pressure sensor and its connection from moisture and frost buildup that can cause false low oil level faults. Install the oil pressure sensor boot in locations where the ambient temperature drops below 0°C (32°F). See Figure 14 for illustrations of the installed kit. Follow the instructions provided with the kit to install the boot. Oil pressure sensor boot 14 kW Models 20 and 26 kW Models GM102176 Figure 14 Oil Pressure Sensor Boot Location 1.8.6 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). The carburetor heater prevents condensation and carburetor icing. The heater requires a continuous source of AC power. See the generator set Installation manual for more information. Generator set model Voltage 14 kW Models 120 VAC 240 VAC 20 kW Models 120 VAC 240 VAC 26 kW Models 120 VAC Figure 15 Heater Specifications Thermostat ON 4 ± 3°C (40 ± 5°F) 4 ± 4°C (40 ± 7°F) 4 ± 4°C (40 ± 7°F) Thermostat OFF 16 ± 3°C (60 ± 5°F) 16 ± 3°C (60 ± 5°F) 16 ± 3°C (60 ± 5°F) 120 VAC plug 240 VAC 3-pin Mate-N-Lock connector Thermostat Figure 16 Carburetor Heater with Thermostat and Power Connectors, 14 kW Models GM19463 24 TP-7092 9/23 1/8 NPT threaded fitting 120 VAC plug Heating element Power cord disconnect plug Thermostat 240 volt 3-pin plug GM57968 Figure 17 Carburetor Heater, 20 and 26 kW Models GM88228 1.8.7 Emergency Stop Kit An emergency stop button is available as a loose kit. Pressing the emergency stop button causes the generator set to shut down immediately. The generator controller displays an emergency stop shutdown message after the button is pressed. E-stop assembly harness contains the E-stop, contact block, and two leads connected to the contact block. The harness is factory-assembled. The kit also includes the emergency stop switch decal. The generator set enclosure is designed with an opening for the emergency stop button. Install the emergency stop button as described in the TT-1613 and TT-1795 instructions. RDC2 firmware to version 5.5 or higher is required for E-stop operation. Use a personal computer (laptop) and Kohler® SiteTechTM software or the USB Utility to update the controller firmware, if necessary. See TP-6701, SiteTech Operation Manual, or TT-1636, Firmware Update Using the USB Utility, for instructions if necessary. 1.8.8 Load Management Two optional load management devices are available for use with single-phase generator sets and a model RXT or RDT transfer switch. · The optional Load Shed Kit mounts inside a model RDT or RXT transfer switch. · The combined interface/ load management board is available for the Model RXT transfer switch. The devices provide an automatic load management system designed to comply with applicable NEC requirements (ref. article 702 for Optional Standby Systems). The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes. Note: The load management devices are only compatible with single-phase generator sets. The load management device automatically manages up to six residential loads. Two relays are provided to control two independent air conditioner loads. Up to four power relay modules can be connected for management of non-essential secondary loads. The load management device is controlled by the RDC2 controller. The load on the generator set is monitored, and loads are added or shed in the order of their priority. See the installation instructions provided with the load shed kit or the Model RXT Operation and Installation Manual for more information. TP-7092 9/23 25 1.8.9 PowerSync Automatic Paralleling Module (APM) The PowerSync® Automatic Paralleling Module (APM) allows the use of two Model 14RCA/L or two 20RCA/L generator sets in a single-phase paralleling system to supply power to one building or site. See Figure 18. The APM provides a common connection point for paralleling generators and permits individual control of the generator connections, allowing for synchronization, redundancy, and generator management. Automatic paralleling requires: 1. Two single-phase generator sets. The generator sets must be the same size (kW) and model. 2. APM RDC2.4 paralleling firmware for the blue-board controller on each generator set. Download the latest version of paralleling firmware from the Service Support section of the Kohler Power Resource Center (KPRC). 3. One Model RXT automatic transfer switch (ATS). 4. One Automatic Paralleling Module (APM) kit. 5. A personal computer (laptop) with Kohler® SiteTechTM software is required for system setup. 6. A load management device is required if one generator set cannot support the maximum total load. The load management device (load shed kit or RXT combined interface/ load management board) is necessary in order to shed non-critical loads in the event that one generator set shuts down and the other generator set cannot support all of the loads. See TT-1596, provided with the APM, for complete installation instructions. The APM and associated equipment must be installed by a Kohler® trained and authorized dealer. If the APM is not installed within sight of the generator sets, local codes may require the installation of circuit breakers near the APM. Circuit breaker kits are available for installation inside the APM enclosure. See TT-1596 for the circuit breaker kit numbers. zab26291 Figure 18 PowerSync® Automatic Paralleling Module 1.8.10 Programmable Interface Module (PIM) The optional Programmable Interface Module (PIM) provides two programmable inputs and six programmable dry contact outputs for connection to customer-supplied equipment. The outputs are controlled by the RDC2 controller, and can also be controlled remotely using the OnCue® Plus program. The PIM is mounted in a NEMA 3R aluminum enclosure, which can be mounted indoors or outdoors. See the installation instructions provided with the PIM. 26 TP-7092 9/23 1.9 Service Views 1 2 5 6 3 10 9 15 16 4 14 13 12 11 8 21 18 7 3 22 23 24 25 26 27 17 19 28 7 32 31 20 ENCLOSURE PANELS REMOVED TO SHOW DETAIL 29 30 ADV9746 1. Hinged roof 2. Lock 3. Air intake 17. Oil fill 18. AC receptacle for accessories 19. Oil drain valve 4. Enclosure key, provided with generator set 5. High voltage electrical in 6. Optional emergency stop button location 20. Exhaust outlet 21. Silencer 22. USB connector (for firmware updates) 7. Lifting holes 8. Fuel inlet 23. RDC2 controller 24. Line circuit breaker 9. Air intake 25. Field-connection terminal block (behind panel) 10. Low voltage electrical in 11. Oil pressure switch 26. Digital spark advance ignition (DSAI) lead location (14RCA/L only) 27. Thermostat location 12. Oil check (dipstick) 28. Fuel system 13. Air cleaner 14. Nameplate location 29. Battery cables (provided) 30. Engine starting battery location (battery purchased separately) 15. Oil filter (20 kW models) 31. Oil drain hose (shown in storage position) 16. Auxiliary winding circuit breaker 32. Oil filter (14 kW models) Figure 19 Service Views (20 kW model shown) TP-7092 9/23 27 1 2 5 6 3 10 8 4 15 14 13 12 12 13 9 16 23 187 10 24 25 3 26 27 28 18 19 20 10 31 21 22 29 30 ENCLOSURE PANELS REMOVED TO SHOW DETAIL ADV9919 1. Hinged roof 2. Lock 3. Air intake 4. Enclosure key, provided with generator set 5. Optional emergency stop button location 6. High voltage electrical in 7. Low voltage electrical in 8. Air intake 9. Fuel inlet 10. Lifting holes 11. Oil check (dipstick) 12. Oil filter (26 kW models) 13. Oil pressure switch 14. Air cleaner 15. Auxiliary winding circuit breaker 16. Engine shutdown switch 17. AC receptacles for accessories (not shown) 18. Oil fill 19. Three-pin connectors for accessories 20. Oil level switch 21. Oil drain valve 22. Exhaust outlet 23. Silencer 24. USB connector (for firmware updates) 25. RDC2 controller 26. Line circuit breaker 27. Field-connection terminal block 28. Fuel system 29. Battery cables (provided) 30. Engine starting battery location (battery purchased separately) 31. Oil drain hose (shown in storage position) Figure 20 Service Views (26 kW model shown) 28 TP-7092 9/23 Section 2. Generator Set Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine. Air Inlets. Check for clean and unobstructed air inlets. Battery. Check for tight battery connections. Consult the battery manufacturer's instructions regarding battery care and maintenance. Exhaust System. Check for exhaust leaks and blockages. Check the muffler condition. · Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections. · Check for corroded or broken metal parts and replace them as needed. · Check that the exhaust outlet is unobstructed. Oil Level. Check the oil level before starting the generator set and at the intervals given in the Scheduled Maintenance section. Maintain the oil level at or near, not over, the full mark on the dipstick. Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set. 2.2 Exercising the Generator Set Operate the generator set without load once each week for 20 minutes. See the Exercise section for information about loaded and unloaded exercise modes. For instructions to set the exerciser, see the Setting the Exerciser section. 2.3 Generator Set Operation DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings. TP-7092 9/23 29 Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: · Light-headedness, dizziness · Physical fatigue, weakness in joints and muscles · Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision · Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air. Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building's occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer's instructions. CAUTION Hot surfaces. Remind family members, children, and visitors to use caution near the generator set. Generator sets connected to automatic transfer switches will start automatically during exercise periods and power outages. Some generator components become hot when the generator is running and remain hot for a time after the generator set shuts down. 2.3.1 Local Starting and Stopping Start: Press the RUN button to immediately start the generator set. Stop: Press the OFF button. The engine stops. Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown. 2.3.2 Automatic Operation An automatic transfer switch monitors the utility power and signals the generator set to start when utility power is lost. The ATS then transfers the load to the generator set. When utility power is restored, the transfer switch transfers the load back to utility, runs the generator set with no load to cool down the engine, and then stops the generator set. See the Automatic Operation with Model RXT Transfer Switch section and Automatic Operation with Other Transfer Switches section for more information about automatic operation. 2.3.3 Remote Starting and Stopping A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set. Close the switch to start and run the generator set. Open the switch to stop the generator set. Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown. 2.3.4 Remote Emergency Stop Switch The generator set may be connected to an optional remote emergency stop switch. See Figure 21. The remote emergency stop switch may be mounted near the generator set or in a remote location. If the emergency stop button is activated, the controller display will show Emerg Stop Shutdwn. 30 TP-7092 9/23 Emergency Stop Switch Operation Press the red STOP button to shut down the generator set in an emergency. Using the emergency stop button bypasses the engine cooldown cycle, stopping the engine immediately. The controller emergency stop lamp lights (if equipped) and the unit shuts down. The generator set cannot be restarted until the emergency stop switch(es) is/are reset. Lockout/Tagout The emergency stop button can be locked in the STOP position. Insert a lock through two openings in the yellow shroud to prevent the stop button from being pulled out. See Figure 21. Remove the lock for normal operation. A lock is not required in order to keep the switch activated. The switch button will stay depressed until it is pulled out by the operator. Resetting the Emergency Stop Switch To reset the E-stop switch, remove the locking device and pull the button out. Reset the controller by pressing the OFF/RESET button. Two openings in the shroud for customerprovided lockout/ tagout device Stop button Figure 21 Emergency Stop Switch (optional) Two openings in the shroud for customerprovided lockout/ tagout device GM103743 Shutdown Switch The generator set may be equipped with a Shutdown switch. See Figure 22. This switch, also referred to as the Engine Shutdown switch, commands an immediate shutdown and prevents an engine start if the switch is moved to the off (open, O) position. When the shutdown switch is activated, the controller display shows Emerg Stop Shutdwn. The switch is a mechanical, rocker-style switch. Press O to prevent engine start during generator set service. Press I to allow the engine to start and run. See Figure 22 for switch connections. Figure 22 Shutdown Switch TP-7092 9/23 I = On. The engine is allowed to start. O = OFF. Engine shuts down, will not start. dwg GM111084 31 2.3.5 Engine Start Crank Cycle The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See the Faults section. Cranking 1, 2, and 3 are displayed during the crank cycle. Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle. 20 and 26 kW Models (RDC2.4 v 1.4.4 or later) For RDC2.4 controllers with firmware version 1.4.4 or later, the 20 and 26 kW models will perform two crank cycles with 3 starting attempts during each cycle. The controller attempts to start the generator set three times (three starting attempts, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the controller pauses for 45 seconds, and then performs another set of 3 starting attempts. If the generator set does not start during these crank cycles, the system shuts down on an overcrank fault. See the Faults section. 2.3.6 Engine Cooldown The engine cooldown time delay allows the engine to run after the loads have been removed. The engine cooldown time delay is set to 5 minutes. The engine stops before the cooldown time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises above the high limit during the cooldown cycle. If a transfer switch other than the Model RXT is used, an additional engine cooldown time delay may be programmed on the transfer switch. To allow the smart engine cooldown on the RDC2 controller to operate most efficiently, set the cooldown time on the transfer switch controller to zero or the minimum time allowed. Refer to the instructions provided with the transfer switch for more information. 2.3.7 Automatic Operation with Model RXT Transfer Switch The Model RXT transfer switch connects to the RDC2 controller through the ATS interface board on the transfer switch. Also see the Model RXT Transfer Switch Operation/Installation Manual for more information about transfer switch operation. The controller must be in AUTO mode for automatic transfer switch operation. Automatic Start The RDC2 controller receives utility source voltage sensing data from the Model RXT transfer switch. 1. If the utility source voltage falls below an acceptable level, the controller starts the engine start time delay. 2. If the utility source is not restored before the time delay expires, the generator set starts. 3. After the Normal-to-Emergency time delay, the ATS is signaled to transfer the load to the emergency source. Automatic Stop with Engine Cooldown 1. When the utility source is restored, the Emergency-to-Normal time delay starts. 2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility. 3. The generator set runs through the engine cooldown cycle and then stops. 2.3.8 Automatic Operation with Other Transfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT) is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set. The controller must be in AUTO mode to respond to remote start/stop signals from an ATS or remote switch. Press the AUTO button to put the controller into automatic mode. Automatic Start The engine start contacts on the ATS close to signal the generator set to start, and remain closed while the generator set is running. 32 TP-7092 9/23 Automatic Stop The engine start contacts on the ATS open to signal the generator set to stop. 2.4 Exercise The RDC2 controller can be set to automatically run the generator set at the same time and day each week. Weekly, bi- weekly, or new monthly exercise is required to keep the engine and alternator in good operating condition. Three exercise modes are available for all RCA models: unloaded cycle with system diagnostics, unloaded full speed, and loaded full speed (requires an RXT ATS). An additional 90-second EcoExercise cycle is available for the 26RCA/L. The exercise modes are described in more detail in the following sections. A loaded exercise can be set at the RDC2 controller only if a Model RXT transfer switch is connected. Note: With transfer switches other than the Model RXT, it is possible to have two exercise settings (one unloaded exercise set at the generator set controller, and another exercise set at the ATS controller). If the exercise times overlap, the ATS exercise setting takes priority. If a transfer switch other than the Model RXT is used, refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS, if desired. 2.4.1 Setting the Exerciser When power is applied to the RDC2 controller (that is, when the battery is connected), you will be prompted to set the date and time, select a language, and then to set the exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. See the Changing Settings section for more detailed instructions to change settings on the RDC2. See the Setting the Exerciser section for more detailed instructions to set the exerciser or change the exercise settings. 2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded exercise runs the generator set without signaling the transfer switch to transfer the electrical load from the utility source to the generator set. The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the default exercise setting. The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 23 and described below. · Runs at reduced speed for 10 minutes to warm up and exercise the engine. · Ramps up and runs at full speed for 3 minutes. Engine diagnostics are performed during this full-speed portion of the cycle, which provides the best test of engine and alternator power backup capability. Diagnostic tests at full speed can identify potential problems with the power output and alert the operator before an emergency event. · Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically. 3 min. Engine Speed, RPM 1 min. 1 min. 10 min. Engine Exercise Figure 23 Unloaded Exercise Cycle Full-Speed Diagnostics 5 min. Cooldown TP-7092 9/23 33 System Diagnostics During the unloaded exercise, the controller monitors the following data. The controller display indicates that the generator set is running, unless a fault is detected as described below. · ATS connection. The controller verifies that the Model RXT ATS interface board is connected. · Battery voltage. Battery voltage is checked before exercise to verify engine starting capability. Battery voltage provides a measurement of battery health. If the controller detects low battery voltage, the condition is indicated on the display. · Communication integrity tests. J1939, RBUS, Ethernet, and USB are monitored for messages indicating that the controller and wiring are reliable. · Engine speed. Engine speed is measured at reduced speed and full speed. An overspeed or underspeed condition will result in a fault condition and shutdown. · Generator output frequency and voltage. Operating the generator at full speed allows the RDC2 controller to check the output power for correct voltage, frequency, and stability. When the engine is running at full speed, the controller verifies that the voltage and frequency are within acceptable limits. A fault message is displayed if the voltage or frequency is out of range. · Oil pressure. Oil pressure is verified to ensure proper lubrication of critical engine components. Pressure is monitored at both reduced and full speeds. If the oil pressure is low, the Low Oil Pressure message is displayed and the generator set shuts down. · Oil level sensor. The 26RCA/L model uses an oil level sensor that will shut down the engine or will not allow the engine to start if the oil drops below a certain level. 2.4.3 EcoExercise (26RCA/L only) A new 90 second EcoExercise cycle is available for the 26RCA/L model only. Its main features are: · Lowers the fuel cost. · In cold temperatures, limits condensation build- up in the crankcase. The EcoExercise Cycle runs for 60 seconds at 3600 RPM with active diagnostics, and 30 seconds at reduced speed. Monthly EcoExercise cycles are recommended for cold climates. 2.4.4 Unloaded Full-Speed Exercise The unloaded full-speed exercise runs the generator set at full speed for 20minutes without transferring the load. To set an unloaded full-speed exercise, follow the procedure in the Changing the Exercise Settings section and select Exercise Mode: Unloaded Full. 2.4.5 Loaded Full-Speed Exercise (with RXT only) A loaded exercise starts the generator set, ramps up to full speed, and then transfers the electrical load from the utility source to the generator set. After 20 minutes, the load is transferred back to the utility source. The engine runs without load for 5 minutes or until cool, and then shuts down automatically. Note: With a loaded exercise, power to the building is lost for up to 10 seconds during load transfer. For a loaded exercise controlled by theRDC2 controller, a Model RXT transfer switch must be connected to the generator set. To set a loaded exercise, follow the procedure in the Changing the Exercise Settings section and select Exercise Type: Loaded. For a loaded exercise with a transfer switch other than a Kohler® Model RXT, program the exercise at the transfer switch controller. Refer to the transfer switch operation manual for instructions. 34 TP-7092 9/23 2.4.6 Shutdown During Exercise (Advanced Diagnostic) The following advanced diagnostic operation applies to RDC2 controllers with firmware versions 5.04 and higher. If the generator set shuts down on a fault during an exercise, the controller will try to restart the engine. If the engine starts, the generator set will run at full speed for two minutes and then stop. The event history will show Advanced Diagnostic Active. The exercise schedule is maintained. If the engine does not start, the shutdown message will be displayed. Correct the fault condition and reset the fault as described in the Faults section. 2.4.7 Power Failure During Exercise Cycle If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode. If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode. The generator set continues to run and supply power to the load for the duration of the utility power outage. When Utility power is restored, the ATS will re-transfer to the utility source through normal timing sequences. 2.5 Faults The RDC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in the Resetting the Controller After a Fault Shutdown section. Contact an authorized dealer for service, if necessary. 2.5.1 Warnings The controller displays a fault message but the generator set does not shut down on a warning. The controller resets automatically after a warning condition is corrected. 2.5.2 Shutdowns Under a fault shutdown condition, the generator set shuts down automatically and the controller displays a fault message. The OFF LED flashes. In some cases, the engine cooldown cycle runs before the engine shuts down. See the Resetting the Controller After a Fault Shutdown section. Shutdown switches (such as the low oil pressure switch or low oil level (26RCA/L only) or high engine temperature switch) on the generator set will automatically reset when the problem is corrected. However, the fault condition at the controller does not clear until the controller is reset. The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See the Resetting The Controller after a Fault Shutdown section for instructions to reset the controller after a fault shutdown. 2.5.3 Shutdown During Exercise (Advanced Diagnostic) If the generator set shuts down on a fault during an exercise, the controller will try to restart the engine. If the engine starts, the generator set will run at full speed for two minutes and then stop. The event history will show Advanced Diagnostic Active. The exercise schedule is maintained. If the engine does not start, the shutdown message will be displayed. Correct the fault condition and reset the fault as described in the Faults section. 2.5.4 ATS Communication Errors When a Model RXT transfer switch is used, an ATS fault indicates that the connection to the interface board on the transfer switch has been lost. Check the connection to the ATS interface board. TP-7092 9/23 35 2.5.5 Resetting the Controller After a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 25 to identify and correct the fault condition before proceeding. Contact an authorized dealer for service, if necessary. RDC2 Controller Reset Procedure Press the OFF button to reset the controller, or follow the procedure below. See Figure 24. 1. While the fault message is displayed, press the Select button to go to the Overview menu. 2. Press Select again. The active fault message is displayed. 3. Press Select. Confirm Clear Fault: NO is displayed. 4. Press the UP arrow button. Confirm Clear Fault: YES is displayed. 5. Press the Select button to enter YES and clear the fault. 6. Press the Select button to return to the overview menu. The controller changes to OFF mode. 7. Press AUTO to put the generator set into automatic mode. Fault Message Overview ---> 1.2 h Figure 24 Clearing a Fault on the RDC2 Controller Fault Message Confirm Clear Fault: NO Press UP arrow button. Confirm Clear Fault: YES tp6809 36 TP-7092 9/23 Fault Message AC Sens Loss Accy PwrOver Warning Advanced Diagnostic ATS ComError ATS PhaseRot Aux Input Batt Chg Flt Battery CrLo Warning Battery Voltage High Battery Voltage Low Engine Speed High Engine Speed Low Exer Not Sch Frequency High Frequency Low Lo Crank Vlt Locked Rotor MainPwrOverL Warning (W) or Shutdown (SD) W (1 sec.) SD (3 sec.) * W SD W W SD * W W W W SD * SD * W SD * SD * W SD SD Condition Check AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect. Warning: after 1 second if no output detected after crank disconnect. Shutdown: after 3 seconds if voltage was present and then lost. Accessory Power Overload. An over current fault (short circuit) on the accessory controller power output. Shutdown during the reduced speed portion of an exercise. The event history will show Advanced Diagnostic Active. The engine then restarts, runs at full speed for 2 minutes, and stops. The controller returns to AUTO mode. The exercise schedule does not change. ATS communication error. Warning is displayed if ATS interface connection is lost. See the section title: ATS Communication Errors. ATS phase rotation mismatch. Transfer switch phase rotation does not match, ATS will not transfer. Auxiliary input. An optional customer-connected input is closed. (Digital input from optional PIM.) Battery charger fault. Input to PIM from an external battery charger (not the built-in battery charger). Engine starting battery voltage falls below 11 VDC for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. Engine starting battery voltage rises above 16 VDC for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. Engine starting battery voltage falls below 12.5 VDC for more than 90 seconds when the engine is not running. Not operative during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. Engine speed exceeds 115% of the normal running speed for more than 0.3 seconds. Engine speed drops below 85% of the normal running speed for more than 3 seconds. Exercise not scheduled. No exercise is scheduled on the controller. Governed frequency exceeds 110% of the system's frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Low cranking voltage. Battery voltage dropped below 3.5 VDC during engine cranking. No engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected. Main power overload. An over current fault on the 70 controller output (short circuit). Contact an authorized dealer for service. Contact an authorized dealer for service. If the generator set does not restart and return to AUTO, check for other faults that prevent generator set operation. Check communication wiring between transfer switch interface board and generator set. Correct the ATS connection. Refer to the ATS Installation manual, wiring diagrams, and labels on the transfer switch. Check customer-supplied equipment. Check external battery charger. Check the battery rating and condition. Check the battery charger operation. Charge or replace the battery. Check the battery rating and condition. Check the battery charger operation. Check the battery rating and condition. Check the battery charger operation. Charge or replace the battery. Contact an authorized dealer for service. Reduce the load. Check enclosure thermostat and reset if tripped. Contact an authorized dealer for service. See the Setting the Exerciser section for instructions to set the exerciser. Contact an authorized dealer for service. Reduce the load and restart the generator set. Check enclosure thermostat and reset if tripped. Contact an authorized dealer for service. Charge or replace the battery. Check the battery. Check for loose connections. Contact an authorized dealer for service. Contact an authorized dealer for service. TP-7092 9/23 37 Fault Message Not in Auto Low Oil Level or Oil Pressure Warning (W) or Shutdown (SD) W SD * Condition The generator set is not in Automatic (standby) mode. Remote start and stop commands from a transfer switch or remote switch will be ignored. The oil level switch on the 26RCA indicates low oil level. The LOP switch indicates low oil pressure for more than 5 seconds. Function becomes active 30 seconds after crank disconnect (30 second inhibit). Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in the Scheduled Maintenance section. Over Crank SD Three unsuccessful starting attempts. Spd Sens Flt Volts L1-L2 High SD SD * Engine speed sensor has failed or engine stalled. Generator voltage high. Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds. Volts L1-L2 Low SD * Generator voltage low. Output voltage falls below 80% of the nominal system voltage for more than 10 seconds. Engine cooldown runs before shutting down. Figure 25 Controller Fault Messages Check Press AUTO to place the generator set in Automatic mode, when appropriate. Check for leaks in the lubrication system. Check the oil level and add oil if the level is low. Check the oil level or oil pressure switch and wiring. If the fault persists, do not run the generator set. Contact an authorized dealer for service. Check the fuel supply, spark plug, and battery. Check for loose connections. Contact an authorized dealer for service. Contact an authorized dealer for service. Contact an authorized dealer for service. Reduce the load and restart the generator set. Check enclosure thermostat and reset if tripped. Contact an authorized dealer for service. 38 TP-7092 9/23 2.5.6 Faults Related to Paralleling If the PowerSync® Automatic Paralleling Module (APM) is used with two 14 kw or two 20 kW generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus. This section lists those faults and events. See the installation instructions provided with the APM for additional paralleling information. Note: Contact an authorized dealer for paralleling system installation, startup, troubleshooting, or service. Fault Text Description When Active Current A High Warning Frequency High Warning Frequency Low Warning Reactive Power Low Warning Real Power High Warning Real Power Low Warning Over Current Over Frequency Under Frequency Loss of Field Over Power Reverse Power Paralleled Paralleled Paralleled Paralleled Paralleled Paralleled Voltage L1-L2 High Warning Voltage L1-L2 Low Warning Over Voltage Under Voltage Paralleled Paralleled Pressing OFF will stop the generator set. Figure 26 Warning Messages (protective relay disconnect) Warning Delay, sec. 10 10 10 10 10 10 10 10 Display Cleared On Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Press AUTO or OFF * Fault Text BusDeadLive BusLiveDead CfgModelNum CfgSysVolt ChkngMeter ConCheckFail ConChecking ConNotDeterm ContactorOk ErraticSig LossOfComAPM Description The bus is measured to be dead when one of the generators is supposed to be supplying voltage to the bus (closed contactor) The bus is measured to be live when no generators are connected to it (both contactors open). The two generators that are intended to be paralleled have incompatible model numbers. The system voltage of the two generators intended to be paralleled is not the same. Because the system does not know which voltage is correct, the generators will not be allowed to start. This generator has paralleled to the other generator and is verifying that the metering is connected and establishing the connection direction. Failure to Auto-Discover APM connections. Performing APM connection auto-discovery. APM connection auto-discovery is not complete. This means that the generator does not know which contactor is connected to it. Successful auto-discovery of APM connections. The power metering on this controller gives a signal that is not consistent with the system configuration. Reversing the power direction does not resolve the problem. The Automatic Paralleling Module has stopped communicating on RBUS. (An APM was detected on the RBUS network but is no longer communicating). Possible Causes * Bus metering V9A and V9B connections to V9 of paralleling protection harness are connected incorrectly. Bus metering V9A and V9B connections to V9 of paralleling protection harness connected incorrectly. Incorrect configuration of one of the generators. Different generator types. The paralleled generator sets must be the same kW model. (i.e. two 14 kW or two 20 kWor 26 kW models). One of the two generators is incorrectly configured. Intermittent connections on RBUS network wiring. Status message appears the first time the two generators are paralleled. Wires 9A and 9B crossed between the generators. Wires 9A or 9B not connected. This generator has started in RUN, the other generator is in OFF. Generators not yet started in RUN with other generator in OFF. See the APM instruction sheet for instructions to perform the auto-discovery procedure. Auto-discovery was activated by placing other generator in OFF and this generator in RUN. Bad wiring to the CT. Too much tension on wires from the CT to the controller. APM is unplugged. Primary controller is powered down. Check the battery connections. See previous page for more information. Intermittent connections on RBUS network wiring. Check RBUS communication connections. TP-7092 9/23 39 Fault Text LossOfComm2 LossOfField Description The primary controller has lost communication with the secondary controller. (A secondary controller was detected, then communication was lost.) This generator has absorbed more than 25% reactive power (magnetic excitation current) for 20 seconds. Possible Causes * RBUS disconnected, secondary controller battery disconnected, updating firmware in secondary controller, or intermittent RBUS connections. Generator voltage on this generator is not calibrated correctly. Generator voltage on other generator is not calibrated correctly. Bus voltage on this generator is not calibrated correctly. Bus voltage on the other generator is not calibrated correctly. MeteringOk MeterUnknown NoCurrent The generator has verified that the metering is connected correctly and that the direction is consistent with expected power direction. This generator does not know if the metering is connected or the orientation of the connection. This means that the generators can't share load accurately until this information is known. The generator has applied load (using the other generator) and has observed no current on the power sensing inputs. SyncFailure The generator has been attempting to synchronize for over 2 minutes without success. For paralleling system troubleshooting and service, contact an authorized dealer. Figure 27 Events Related to Paralleling Status message indicates that the CT is connected to the generator correctly. System commissioning and startup not yet complete. See the APM instructions. The CT is not connected to the controller. The output leads from the generator do not go through the CT in the correct direction. See the APM instructions. Generator is hunting. Advanced speed control settings need adjustment. Load is changing frequently to disturb the online generator. Generator Set State Generator Management Off Protective Relay Tripped Contactor Synchronizing Unloading Description This generator has been stopped by generator management because it is not presently needed to supply the load. The generator is available and will start if it is needed again. The contactor has been forced to open to protect one of the generators or the customer's load. The generator is actively trying to match frequency, voltage and phase with that of the paralleling bus. The generator is actively trying to transfer load from itself to the other generator. Figure 28 Generator Set States Related to Paralleling 40 TP-7092 9/23 Section 3. RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller Model RCA and RCAL generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components: · Model RCA or RCAL generator set · Model RXT Automatic Transfer Switch (ATS) · Load management device · Programmable Interface Module (PIM) The RDC2 controller features include: · Two-line x 16 character backlit digital display with adjustable contrast · OFF, AUTO, and RUN generator set master control buttons · Generator set status indicating LEDs (OFF, AUTO, RUN) · Up, Down, and Select buttons for navigation through menus and adjustments · Power system indicator LEDs to show utility and generator source status, and to show which source (utility or generator) is supplying power to the load (Model RXT automatic transfer switch is required for operation of these LEDs). 3.2 Control and Indicators Figure 29 illustrates the RDC2 controller. See Figure 30 for details of the controller's user interface. User interface (see Figure 30) Figure 29 RDC2 Controls and Indicators GM89864 TP-7092 9/23 41 2-line LCD display AUTO button and LED OFF button and LED Up button Select button Down button RUN button and LED Utility power available LED* Building on utility power LED* Generator power available LED* Building on generator power LED* These LEDs operate only if a Model RXT automatic transfer switch is connected. GM77569 Figure 30 RDC2 User Interface 3.2.1 Controller Keypad The RUN, OFF, and AUTO buttons control the generator set as described in Figure 31. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See the Generator Set Operation section for operation instructions. Button Button Function RUN OFF AUTO Down arrow Select Up arrow Starts the generator set. The engine start time delay is ignored. Stops the generator set. The cooldown time delay is ignored. During the engine crank cycle, pressing OFF will stop the crank cycle. Press OFF to clear faults and reset the controller. Places the generator set in Automatic (standby) mode. Use to navigate through menus and change settings. This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller. Figure 31 RDC2 Controller Pushbutton Operation 42 TP-7092 9/23 3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 32. Power System LEDs indicate the status of the utility power and the generator set, and indicate which source is supplying power to the building (based on the position of the RXT transfer switch). See Figure 32. Note: The power system LEDs operate only if a Model RXT transfer switch is connected. LED LED Operation RUN OFF AUTO Utility Power Available * Building on Utility Power * Generator Power Available * Building on Generator Power * Lights when the generator set has been started locally by pressing the RUN button. Remote start and stop commands are ignored. Lights for 2 seconds, then flashes every 2 seconds when the generator set and controller are off. Remote start/stop commands have no effect. The exercise cycle will not run. In Auto mode, OFF LED flashes quickly to indicate a fault shutdown. Attention required. Identify and correct the fault condition before resetting the controller. Lights when the generator is in automatic (standby) mode. Generator set will respond to engine start and stop commands from the controller (for example, exercise start and stop commands) or an ATS. Time delays operate as described in the Generator Set Operation section. Lights when utility power is available. Lights when the building load is connected to utility power through the RXT transfer switch. Lights when generator power is available. Lights when the building load is connected to generator power through the RXT transfer switch. These LEDs operate only if a Model RXT transfer switch is connected. Figure 32 RDC2 Controller LED Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16-character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 33. When the system is in standby mode and the controller is in AUTO, the screens shown in Figure 33 are displayed. When a fault or warning condition exists, the controller will show the corresponding message. See the Fault section for more information about faults. Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. See the related sections in the manual for menu diagrams. The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast screen. Press the Select button, and then use the up and down arrow buttons to adjust the contrast. See the related sections in the manual, Changing Settings, and Genset System Menu. The display backlight turns off after about a minute of no activity. The backlight turns on when a button is pressed or when the generator set starts. TP-7092 9/23 43 Active Alert Genset Status Running Voltage: 240V Freq: 60.0 Hz Engine: 72.0F Oil Pressure: OK Battery 12.3V Active Alert Genset Status Standby Battery 12.3V Engine Runtime: 24.5 h Date: 02DEC2011 Time: HR:MNpm Engine Runtime: 24.5 h Next Exercise: 09:00p 09Dec2011 Date: 02DEC2011 Time: HR:MNpm Next Maintenance: 150 h or Mar2012 Generator running Figure 33 Autopaging Displays, Generator Running and Automatic Mode Automatic mode Sample data shown. 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery. If controller power is disconnected and reconnected, you will be prompted to set the language, time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. Repeat until all settings are saved and the controller returns to the main menu. See the Changing Settings section for more detailed instructions to change settings on the RDC2. See the Setting the Exerciser section for more detailed instructions to set the exerciser or change the exercise settings. 3.4 Battery Charging The controller includes a built-in battery charger to maintain the engine starting battery. The RDC2 controller monitors the battery voltage and provides a constant 13.4 ±2% VDC voltage and maximum 2.5 amps to charge the battery. The installer must connect utility power provided from the building on a breaker-protected circuit for the built-in battery charger as described in the generator Installation Manual. 44 TP-7092 9/23 3.5 Changing Settings Some settings can be changed from the controller keypad. The controller settings and generator set output are factory-set and should not require field adjustment under normal circumstances. Check and adjust the settings and/or output when: · The controller has been replaced. · The voltage requires adjustment for a particular application. · Troubleshooting generator set problems. Have controller setup and adjustment performed only by an authorized dealer or authorized representative. The following procedure explains how to change settings. See the Changing Settings section for an example using the Date and Time settings. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of the controller settings. Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable. Procedure to Change Settings 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. The Genset System menu is used for this example. See the Main Menu section. 3. Press the Select button to enter the genset system displays. See Figure 34. 4. Press the down arrow button to step through the generator set system settings. 5. To change any of the genset system settings, press the Select button. The selected setting flashes. 6. Press the up or down arrow buttons to increase or decrease the setting. 7. When the desired setting is shown, press Select. The value stops flashing. If there are additional adjustable settings on the screen, the next setting flashes. For example, in the date menu, the day, month, and year can be adjusted. 8. Repeat steps 6 and 7 for each setting on the screen. 9. Press the down arrow to step to the next screen. 10. To exit, press the down arrow button until Return is displayed. Press the Select button to exit the menu. 11. Press the AUTO or OFF button to exit the main menu. Note: If no buttons are pushed, the controller exits the menus and returns to the generator set status display after 5 minutes. TP-7092 9/23 45 Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. Press: Display: Overview --> 1.2 h 8. When the correct date is shown, press the Select button. The saved date is shown. Press: Display: Date 03Jan2012 2. Press the down arrow button until the desired menu is displayed. See the Main Menu section. Date and Time are used for this example. Press: Display: Date --> and Time 9. Press the down arrow button to step to the next menu. Press: Display: Time: 01.49pm 3. Press the Select button to enter the Date and Time menu. Press: Display: Date 05Dec2011 4. To change the date and time settings, press the Select button again. The year will flash. Press: Display: Date 05Dec2011 5. Press the up or down arrow buttons to change the year. Press: OR Display: Date 05Dec2012 6. When the correct year is shown, press the Select button. The year is saved and the next setting (month) flashes. Press: Display: Date 05Dec2012 7. Repeat steps 5 and 6, using the arrow and select buttons to set the month and the date. Figure 34 Changing Settings 10. Repeat steps 5 and 6, using the arrow and select buttons to set and save the time. Note: To change from am to pm, press the up arrow key to increase the hour until the correct hour and pm is displayed. 11. In the time format menu, press Select and then press the up or down arrow button to change the format, 12 hr. or 24 hr. Press Select to save the displayed format. 12. Press the down arrow button. Return is displayed. Press: Display: <-- Return 13. Press Select to return to the Date and Time menu. Press: Display: Date --> and Time 14. Press the Up or Down arrow buttons to step to a different menu. 15. Press Auto to signal the controller to exit the menus and return to the generator set status display. Press: AUTO Display: Genset State Standby Note: If no buttons are pressed, the controller returns to the status display after 5 minutes. 46 TP-7092 9/23 3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Controller Power-up When battery power is connected to the controller, you will be prompted to set the language, date and time, and then to set the exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. See the Changing Settings section for more detailed instructions to change settings on the RDC2. If the battery is disconnected and reconnected during generator set maintenance or service, the time, date, and exercise settings will need to be re-entered. 3.6.2 Changing the Exercise Settings This section explains how to change the exercise settings after the initial setup. Follow the procedure below and see the flowchart in Figure 35 to set the exercise time and date, mode, and frequency. Procedure to Set the Exerciser 1. Press the AUTO button on the controller. 2. Press the Select button to go to the main menu. See the Main Menu section. 3. Press the down arrow button to step to the Genset System menu. 4. Press the Select button to enter the Genset system menu. See Figure 35. 5. Use the down arrow button to step to the Next Exercise menu. If the exerciser is not set, No Exercise Scheduled will be displayed. 6. Press and HOLD the Select button to enable editing. 7. Press the Select button. The setting flashes to show that it can be changed. For example, HR flashes to show that the hour can be changed. 8. Press the Up or Down arrow buttons to change the setting. 9. Press the Select button to save the setting and move to the next. For example, save HR setting and move to MN. 10. Repeat steps 5 through 9 to change the next item on the line until the desired settings are displayed. 11. Press Select to save after all settings have been selected. Settings will stop flashing. 12. If the generator set is connected to a Kohler® Model RXT transfer switch, the exercise can be changed to a loaded exercise. Set the Exercise Mode to Unloaded Cycle, Unloaded Full, or Loaded Full (RXT ATS required) as shown in Figure 35. Unloaded Cycle is recommended. See the Unloaded Cycle Exercise with Complete System Diagnostic through Loaded Full-Speed Exercise (with RXT only) sections for information about the exercise modes. 13. Set the exercise frequency (weekly or every two weeks). Weekly exercises are recommended. 14. Press the down arrow button to step to the Return menu. Press the Select button to return to the main menu. After a scheduled exercise run, the next exercise time and date will be updated automatically based on the Exercise Frequency setting. Other transfer switches: For a loaded exercise with a transfer switch other than a Kohler® Model RXT ATS, refer to the transfer switch operation manual for instructions. Exerciser Reset To reset the exerciser to run at a different day and/or time or to change the exercise mode, follow the procedure in Changing the Exercise Settings section to change the exerciser settings. TP-7092 9/23 47 Genset - - > System System Freq: XX.X Hz System Phase System Volt System Battery Fuel Type Next Exercise * HR:MN PM MM/DD/YY HOLD: Next Exercise HR:MN PM MM/DD/YY Exercise Mode: Loaded HOLD: Exercise Mode: Unloaded Cycle/Unloaded Full/ Loaded Full Exercise Freq: Weekly HOLD: Exercise Freq: Weekly/Bi-Weekly Language: Contrast: 50 <- - Return If the exerciser has not been set, No Exercise Sch will be displayed. Figure 35 Procedure to Set the Exerciser on the RDC2 Controller tp6804 48 TP-7092 9/23 3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. Status information, including the engine runtime, cannot be changed by the operator. Diagrams in the following sections show how to navigate through the menus. The diagrams show sample settings. Settings for your application may vary. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of the controller settings. Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable. If a setting on the controller display is flashing, edit mode has been enabled. Press the OFF or AUTO button to exit the edit mode. 3.8 Main Menu Press the Select button once to bring up the main menu. Overview is displayed. See Figure 36. Press the down arrow button to step to the next menu, Engine Metering. Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 36. The controller will exit the main menu after 5 minutes if no buttons are pressed. To exit the main menu immediately, press the controller's OFF or AUTO button. Status Displays Overview ---> 1.2 h Press the Up and Down arrow buttons to move between menus. Press OFF or AUTO to exit the menus. Engine ---> Metering Generator ---> Metering ATS ---> Configuration * Date ---> and Time Genset ---> Information Network ---> Information Genset ---> Run Time Genset ---> System ATS ---> Status PIM ---> Status Load ---> Control Event Log ---> ATS Configuration appears only if a Model RXT transfer switch is connected. PIM Status appears only if a programmable interface module is connected. Load Control appears only if a load management device is connected. Figure 36 RDC2 Main Menu tp6804 TP-7092 9/23 49 3.9 Overview Menu Overview ---> 1.2 h Note: Actual settings may vary. Figure 37 Overview Menu 50 Active Alert (if any) Genset Status Standby Voltage: 240V Freq: 60.0 Hz Engine: 72F Oil Pressure: OK Battery: 12.0V Engine Runtime: 24.5 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Next Maintenance: 150 h or Mar2012 SW Version: 4.07 <--- Return Tp6804 TP-7092 9/23 3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 38. This menu displays status information only. No settings can be changed from this menu. Engine ---> Metering Eng Speed: 3600 RPM Note: Actual settings may vary. Figure 38 Engine Metering Menu Oil Pressure: Switch: OK Oil Temperature: 72.0 F Battery: 12.0 V <--- Return tp6810 TP-7092 9/23 51 3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See the figure titled: Generator Metering Menu. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. Voltage Calibration The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized dealer for service. The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration, if necessary. See Figure 39. Generator --> Metering Three-phase Volts L1- L2: 240 V Volts L2- L3: 240 V Volts L3- L1: 240 V Frequency: 60.0 Hz Single-phase Volts: 240 V Frequency: 60.0 Hz Note: Actual settings may vary. Figure 39 Generator Metering Menu Reset Calibration <--- Return Reset Calib? No Reset Calib? Yes tp6810 52 TP-7092 9/23 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed (see Figure 40). No changes are allowed from this menu. Model and serial numbers are factory-set and should not require changes in the field, except in the event that the controller is being replaced. A personal computer running Kohler® SiteTechTM software is required to enter the generator set model number and serial numbers on a replacement controller. Contact an authorized Kohler dealer for service. Genset ----> Information Genset M/N: 20RCA Genset S/N: ######## Controller S/N: ######## <---- Return tp6804 Figure 40 Generator Set Information Menu 3.13 Genset Run Time Menu The data shown in Figure 41 are displayed. No changes are allowed from this menu. Eng Runtime displays the total number of hours that the generator set engine has run. The runtime is not resettable. The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required. The estimated date for the next scheduled maintenance is also displayed. The maintenance reminder intervals are based on the engine manufacturer's recommendation for changing the oil. Refer to the Scheduled Maintenance section, for maintenance instructions. After changing the oil and performing other recommended maintenance, go to the Overview menu to reset the maintenance timer. See the Resetting the Maintenance Timer section for instructions to reset the maintenance timer. Genset ----> Run Time Eng Runtime: 24.5 h Eng Starts: 18 Next Maintenance: 150 h or Mar2014 Note: Sample data shown. Figure 41 Generator Set Run Time Menu TP-7092 9/23 <---- Return tp6810 53 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 42. Generator sets are factory-set and should not require changes to the system settings in the field. A Kohler-authorized dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see the Changing Settings section for instructions to enable editing and change the system settings. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of the controller settings. Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable. Voltage Regulator (VR) Voltage Adj The generator set voltage is factory set and typically does not require adjustment in the field. If voltage adjustment is required, contact a Kohler authorized dealer for service. Refer to the generator set Installation Manual for instructions to adjust the voltage. Fuel Type The fuel type, LP or natural gas, is shown. Do not change the fuel type in this menu unless the generator's fuel system has been converted by an authorized dealer. Setting the Exerciser Use the Genset System menus to set the generator set exerciser. Refer to the Exercise section for instructions to set the exerciser and for more information about exercising the generator set. After a scheduled exercise run, the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting. Language Controllers can be set for the following languages: English, French, Spanish, Dutch, or German. Adjusting the Display Contrast To adjust the display contrast, use the down arrow button to step to the Contrast menu. Press the Select button, and then use the up and down arrow buttons to adjust the contrast. Press the Select button to save the contrast setting. 54 TP-7092 9/23 Genset ---> System Note: Actual settings may vary. Figure 42 Genset System Menu System Voltage: 240 V System Freq: 60 Hz VR Voltage Adj: 240.0 V System Phase: Single System Battery: 12 V Fuel Type: LP Next Exercise 06:30PM 15Dec2011 Exercise Mode: Unloaded Variable Exercise Freq: Weekly Language: English Meas System: English Contrast: 50 <--- Return TP-7092 9/23 Tp6804 55 3.15 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen. The ATS Status menu displays Model RXT transfer switch and source information. The voltage shown in these menus can be calibrated. Follow the safety precautions at the beginning of this manuals. Use a voltmeter to measure the line-to-line voltage and follow the instructions in Figure 43 to calibrate the voltage readings. ATS - - > Status ATS Position: Normal Note: If there is no Model RXT transfer switch connected to the generator set, Remote ATS is displayed and the other screens on this page do not appear. Note: Sample data shown. Normal Status: Not/Acceptable Emerg. Status: Standby Single-phase Normal Volts: 240.0 V Normal Freq.: 60.0 Hz Emerg Volts: 240.0 V Emerg. Freq.: 60.0 Hz Reset Calibration Three-phase Normal Voltage: L1- L2 240 V Normal Voltage: L2- L3 240 V Normal Voltage: L3- L1 240 V Normal Freq.: 60.0 Hz Normal Rotation: Similar screens appear for the emergency source. Reset Calib? No <- - Return Figure 43 ATS Status Menu, with Calibration Reset Calib? Yes tp6810 56 TP-7092 9/23 3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed. Press the up and down arrow buttons to change the value. Press the Select button to save the value shown. Use the up and down arrow buttons to move to the next value to be changed. Repeat the adjustment process until all values are correct. Press the down arrow until Return is displayed. Press the select button to return to the main menu. ATS - - > Configuration Normal Freq: 60 Hz Normal Voltage: 240 V Emerg. Freq: 60 Hz Emerg. Voltage: 240 V Emergency Start: 3 sec Xfer frm Normal 3 sec Xfer from Emerg: 120 sec Note: Actual settings may vary. Figure 44 ATS Configuration Menu <- - Return tp6810 TP-7092 9/23 57 3.17 Date and Time Menu The date and time will typically be set at controller powerup. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 45. Date and Time Date: 02Dec2011 Time: 12:34pm Time Format: 12hr <--- Return To change the date and time, press the Select button. See the Changing Settings section for instructions. Figure 45 Date and Time Menu 3.18 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or load shed kit, and for systems that use the Kohler® OnCue® Plus Generator Management System. RBUS is a proprietary RS-485 communications protocol. The Networking Information menu leads to submenus for network and RBUS communication settings. See Figure 46. Networking ---> Information Networking ---> Status NS See the Network Status Submenu section Networking ---> Configuration RBUS ---> Information NC See the Network Configuration Submenu section RB See the RBUS Information section <--- Return Figure 46 Networking Information Menu 58 TP-6810 TP-7092 9/23 3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue® Plus. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed. To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. Networking- --> Information Networking- --> Status OnCue Status: Connected DHCP: Enabled IP Address: 123.456.789.123 Subnet Mask: 123.456.789.123 Gateway: 123.456.789.123 DNS 1: 123.456.789.123 DNS 2: 123.456.789.123 Ethernet Status: Disconnected OnCue Server: 123.456.789.123 <--- Return Figure 47 Network Status Submenu TP-7092 9/23 59 3.18.2 Networking Configuration Submenu (OnCue® Password) The networking Configuration menu includes settings used for communication with the Kohler® OnCue® Plus Generator Management System. Password Note: Use the OnCue password shown on the controller display for OnCue or OnCue® Plus applications. For the initial OnCue® Plus setup, you will be required to reset the OnCue® password on the RDC2 controller, and then enter it into the OnCue® Plus application. To reset the password, follow the instructions in Figure 48. Note: The password is displayed for only 10 seconds. Be sure to write down the password and serial number. A new password is generated each time the reset password procedure is performed. If the password is reset after the OnCue® Plus system has been set up, the connection will be lost. Disconnect the battery power to the controller, wait a minute, then reconnect power. DHCP Submenu For most applications, the Dynamic Host Configuration Protocol (DHCP) is enabled and the IP settings cannot be changed from the controller keypad. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is required), then the IP parameters can be modified. For applications that require a static IP address, press and hold the select button to enable editing, press the down arrow to disable DHCP, and then step to the next parameters and enter the information. See Figure 48. If an error occurs while setting a parameter, an error message is displayed and then the controller exits the edit mode. Previous settings are preserved. 60 TP-7092 9/23 Networking---> Information Networking---> Status Networking Configuration RBUS - - > Information Reset OnCue Password HOLD Reset OnCue Password? No UP arrow for YES, Down arrow for NO. Reset OnCue Password? Yes Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. S/N: 1234567 New PW: 12345 DHCP: Enabled <--- Return Figure 48 Networking Configuration Submenu HOLD DHCP: Disabled UP arrow to enable, Down arrow to disable. IP Address: 123.456.789.123 Subnet Mask: 123.456.789.123 Gateway: 123.456.789.123 DNS 1: 123.456.789.123 DNS 2: 123.456.789.123 tp6804 TP-7092 9/23 61 3.18.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules: · Model RXT transfer switch · Combined interface/ load management board on the RXT transfer switch · Programmable Interface Module (PIM) · Load shed kit · PowerSync® Automatic Paralleling Module (APM) Networking---> Information Networking---> Status Networking---> Configuration RBUS---> Information <---- Return Figure 49 RBUS Information Submenu Modules Connected: 2 Remote ---> Devices Net Cycle Time: 123ms Module Timeouts: 1234 Module Errors: 1234 <---- Return RD See the Remote Devices Submenu section tp6804 62 TP-7092 9/23 3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: · Model RXT ATS · Programmable Interface Module (PIM) · Load shed kit or combined interface/ load management board on a Model RXT transfer switch · PowerSync® Automatic Paralleling Module (APM) The serial number for the RBUS module is shown on the circuit board inside the module enclosure. From the RBUS Information section Remote ---> Devices S/N: XXXXXXXXX <<*DeviceType*>> S/N: XXXXXXXXX <<*DeviceType*>> <---- Return Module Status: Connected Comm. Errors: 12345 Comm. Timeouts: 12345 Module ID: 12 Firmware Ver.: 4.07 (Dis)Connected: MM/DD/YY 12:12 PM Connected: Displays the date and time that the device was connected. Disconnected: Displays the last date and time of successful communication. Return ---> tp6804 Figure 50 Remote Devices Submenu TP-7092 9/23 63 3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This menu appears only if a PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller's user interface. A personal computer running Kohler® SiteTechTM software is required to change the input and output settings. Contact an authorized dealer for service. The Kohler® OnCue® Plus Management System can be used to turn outputs on and off. See the OnCue® Plus Software Operation Manual for instructions. PIM Status: PIM 1 ---> Input 1 In/Active <--- Return Figure 51 Programmable Interface Module (PIM) Status Menu Input 2 In/Active Output 1: In/Active Output 2: In/Active Output 3: In/Active Output 4: In/Active Output 5: In/Active Output 6: In/Active <--- Return tp6810 64 TP-7092 9/23 3.20 Load Control Menus The Load Control menu displays the status of the load management device inputs and outputs, and allows a test of the load control output relays. This menu appears only if a load management device (load shed kit or Model RXT transfer switch with the combined interface/ load management board) is connected. Generator current is displayed as a percent of the maximum generator capacity. The load control module adds and sheds loads based on the generator current. The test function cycles the relays in the order of their priority. For detailed information, refer to the instructions provided with the load shed kit. For the RXT combined interface/ load management board, refer to the RXT automatic transfer switch Operation and Installation Manual. Load - - > Control Generator Current: 123 % Load - - > Control 1 Test Outputs Push Select (blinking) <- - Return Figure 52 Load Control Status Menu Input 1: In/Active Input 2: In/Active Output 1: Add/Shed Output 2: Add/Shed Output 3: Add/Shed Output 4: Add/Shed Output 5: Add/Shed Output 6: Add/Shed <- - Return tp6810 TP-7092 9/23 65 3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1-1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning (W), shutdown (S), or informational notice (I), the engine hours at the time of the event, and the event description. The time and date for notices (I) are not stored in the controller. Procedure to View Event History 1. Press Select to enter the main menu. 2. Press the down arrow to step down to the event log. 3. Press Select to display the most recent event. 4. Press the down arrow to step to the next event. 5. Use the up and down arrow buttons to view events. 6. Press the Select button to exit the event log. To stop viewing the event history before the last event, press the select button to return to the main menu. Event Log ---> Date MO/DA/YEAR time HR:MN event number, W/S/I, engine hours event name Press UP and Down arrow buttons to scroll through events Date MO/DA/YEAR time HR:MN event number, W/S/I, engine hours event name Press Select button at any time to return to the main menu. Figure 53 Event Log tp6810 66 TP-7092 9/23 WARNING Section 4. Scheduled Maintenance Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative () lead first. Reconnect the negative () lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. 4.1 Scheduled Maintenance Refer to the following service schedules and the runtime hours displayed on the controller display to schedule routine maintenance. Intervals are shown in hours of operation and/or time intervals (i.e. weekly, monthly, quarterly, etc.) Have an authorized dealer service the generator set at the designated intervals in the service schedule for the life of the generator set. Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently. Contact an authorized dealer for parts. TP-7092 9/23 67 4.1.1 Service Schedule, 14 kW Models System Component or Procedure Fuel Flexible lines and connections Main tank supply level Fuel piping Lubrication Oil level Visually Inspect X X X Crankcase breather hose X Change oil Replace filter Cooling Air ducts, louvers Exhaust Line Leakage X Insulation, fire hazards X Obstructions or combustible materials near exhaust outlet X DC Electrical System Check battery charger operation, charge rate X Remove corrosion, clean and dry battery and rack X Clean and tighten battery terminals and inspect boots X Battery electrolyte level and specific gravity * AC Electrical System Tighten control and power wiring connections Remote control system, if equipped Visible wear or damage X Wire abrasions where subject to motion X Wire-cable insulation condition X Engine and Mounting Visible wear or damage X Air cleaner service Spark plugs Replace stepper motor coupling and bushing Generator Visible wear or damage X Exercise generator set Brushes and collector ring D Measure and record resistance readings of windings with insulation tester (Megger®, with SCR assembly or rectifier and load leads disconnected)* General Condition of Equipment Evidence of vibration, leakage, unusual or excessive noise, temperature, or deterioration X Interior of sound enclosure X Not necessary for maintenance-free batteries. Service more frequently under extremely dusty/dirty conditions. Megger® is a registered trademark of Biddle Instruments. Procedure Check Change Clean R X X X X X X X X X X X X 150 300 300 D D X X X X Action D Authorized dealer only R Replace as necessary Test X X D Frequency Quarterly Weekly Yearly Every 8 hours. of engine operation Yearly or 500 hours Yearly or 100 hours Yearly or 200 hours Yearly Weekly Yearly Weekly Monthly Yearly Yearly Yearly Yearly Monthly Quarterly 6 months 3 years or 500 hours Weekly Yearly or hours shown 500 hours Quarterly Weekly Yearly or 300 hours 3 years Weekly Quarterly 68 TP-7092 9/23 4.1.2 Service Schedule, 20 and 26 kW Models System Component or Procedure Visually Inspect Fuel Flexible lines and connections X Main tank supply level Fuel piping X Lubrication Oil level, 20 kW models Oil Level, 26 kW models Crankcase breather hose X Standard oil change, 20 and 26 kW models Premium oil change, 26 kW models Replace filter Oil Cooler X Cooling Air ducts, louvers Exhaust System Leakage X Insulation, fire hazards X Obstructions or combustible materials near exhaust outlet X DC Electrical System Check battery charger operation, charge rate X Remove corrosion, clean and dry battery and rack X Clean and tighten battery terminals and inspect boots X Battery electrolyte level and specific gravity * AC Electrical System Tighten control and power wiring connections Remote control system, if equipped Visible wear or damage X Wire abrasions where subject to motion X Wire-cable insulation condition X Engine and Mounting Visible wear or damage X Air cleaner service Spark plugs Replace stepper motor coupling and bushing Generator Visible wear or damage X Exercise generator set Brushes and collector ring D Measure and record resistance readings of windings with insulation tester (Megger®, with SCR assembly or rectifier and load leads disconnected)* General Condition of Equipment Evidence of vibration, leakage, unusual or excessive noise, temperature, or deterioration X Interior of sound enclosure X Not necessary for maintenance-free batteries. Service more frequently under extremely dusty/dirty conditions. Megger® is a registered trademark of Biddle Instruments. Procedure Check Change Clean R X X X X X X X X X X X X X X X 150 300 150 300 D D X X X X Action D Authorized dealer only R Replace as necessary Test X X D Frequency Quarterly Weekly Yearly 8 hours of operation 24 hours of operation Yearly or 500 hours Yearly or 150 hours 2 years or 300 hours With each oil change Yearly or 150 hours Yearly Weekly Yearly Weekly Monthly Yearly Yearly Yearly Yearly Monthly Quarterly 6 months 3 years or 500 hours Weekly Yearly or hours shown 500 hours Quarterly Weekly Yearly or 300 hours 3 years Weekly Quarterly TP-7092 9/23 69 4.2 Lubrication System See the service schedules section for oil change and oil filter replacement intervals. See the service views section for the oil drain, oil dipstick, oil fill, and oil filter locations. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative () lead first. Reconnect the negative () lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. 4.2.1 Low Oil Pressure Shutdown The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction. See the Faults section for instructions if the generator set shuts down on a fault. Note: The LOP shutdown feature does not protect against damage caused by operating when the oil level is low; it is not a low oil level shutdown. Check the oil level regularly, and add oil as needed. 4.2.2 Low Oil Level Switch (26RCA) The low oil level switch protects the engine against internal damage if the oil pressure drops below a minimum level. The engine shuts down and a fault message is displayed on the controller if the oil level is too low. See the Faults section for instructions if the generator set shuts down on a fault. Check the oil level regularly and add oil as needed. 4.2.3 Oil Check The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase. To check the oil level, shut down the generator set and wait several minutes. Remove the dipstick and wipe the end clean, reinsert, and remove. See Figure 54. Maintain the oil level between the Add and Full marks on the dipstick. Add oil when the level is low. Note: See the next section for oil specifications. Do not mix oil types when adding oil. Check the oil level before each use. For extended operation, check the oil level periodically as shown in the maintenance schedule for your model. Do not check the oil level when the generator set is running. Shut down the generator set and wait several minutes before checking the oil. 70 TP-7092 9/23 1 1 1 2 2 2 14 kW 1. Dipstick 2. Oil Fill Figure 54 Dipstick and Oil Fill Locations 20 kW 26 kW 7092 4.2.4 Engine Oil Recommendation Use 5W-30 or 10W-30 API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner. For the 26 kW model, 10W-50 extended-life synthetic oil is also available. This premium oil requires fewer oil changes. See the Service Schedule for oil change intervals. 4.2.5 Oil Change Procedure Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Drain the oil while it is still warm. 1. Drain the oil. a. Press the OFF button on the generator set controller. b. Disconnect the utility power to the generator set. c. Disconnect the generator set engine starting battery, negative () lead first. d. Remove the end panels from the enclosure by lifting the panels up and out. Then lift off the service-side panel to access the oil drain valve and hose. e. Clean the area around the dipstick and oil fill cap. f. Remove the oil drain hose from its retaining clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container. g. Open the oil drain valve on the engine. h. Remove the dipstick and oil fill cap. Allow time for the engine oil to drain completely. i. Close the oil drain valve. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip. j. Replace the dipstick. 2. Replace the oil filter. a. Clean the area around the oil filter. b. Loosen the oil filter by rotating it counterclockwise with an oil filter wrench. On 20 and 26 kW models, allow the oil to drain from the filter. Then remove the oil filter. c. Clean the gasket sealing surface of the oil filter adapter. d. Apply a light coat of clean oil to the rubber seal of the new oil filter. e. Install the new oil filter following the instructions provided with the filter. TP-7092 9/23 71 3. Fill with oil. Note: When the oil is drained, some oil remains in the engine. The amount of oil needed to refill the engine may be less than the capacity shown in Figure 55. Use the dipstick to check the oil level during the fill. Do not fill past the full mark on the dipstick. Note: See the Engine Oil Recommendation section for the recommended oil type. Generator Set Model Oil Capacity, L (qt.) 14 kW 20/26 kW 1.8 (1.9) 1.9 (2.0) Figure 55 Engine Oil Capacity a. Add oil through the oil fill port; see the Oil Check section for the oil fill port location. b. Use the dipstick to check the oil level before starting to add the final quart of oil. Fill the engine to the F mark on the dipstick. c. Reinstall the dipstick and the oil fill cap. d. Reconnect the generator set engine starting battery, negative () lead last. e. Reconnect the utility power to the generator set. f. Press the RUN button on the generator set controller. The generator set will start. g. Run the generator set for a minute to allow the oil pressure to reach operating range. h. Stop the generator set, wait 1 minute, and then recheck the oil level. Add oil to bring the level up to the F mark on the dipstick. 4. Check for leaks. a. Check for oil leaks. b. Fix leaks and recheck the oil level. c. Reinstall the housing side panel. 5. Reset the maintenance timer on the controller. 4.2.6 Resetting the Maintenance Timer 1. From the Overview menu, step down to the Genset Run Time menu. 2. Press the Select button and then step down to the Next Maintenance screen. 3. Press the Select button. 4. Press the Up arrow button so that "Reset Maint Timer? Yes" is displayed. 5. Press the Select button. After about two minutes, the new maintenance interval and date are displayed. 72 TP-7092 9/23 4.2.7 Oil Cooler (20RCA/L and 26RCA/L only) Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris. See Figure 56 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud. Clean the outside of the oil cooler fins with a brush or with compressed air. Oil cooler Note: See the Oil Fill Components section for location. 62 590 01 Figure 56 Oil Cooler 4.3 Spark Plugs WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative () lead first. Reconnect the negative () lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. TP-7092 9/23 73 Reset the spark plug gap or replace the plugs with new plugs as necessary. 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. 2. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questionable. 3. Check the spark plug gap using a wire feeler gauge. See Figure 57 for the recommended spark plug gap. Adjust the gap by carefully bending the ground electrode. See Figure 58 and Figure 59. 4. Reinstall the spark plug into the cylinder head. Torque the spark plug to 24.4-29.8 Nm (18-22 ft. lb.) Generator Set Model Spark Plug Gap 14/20/26 kW models 0.76 mm (0.030 in.) Figure 57 Spark Plug Gap 1-514 Figure 58 Checking the Spark Plug Gap Figure 59 Adjusting the Spark Plug Gap 74 1-511 TP-7092 9/23 4.4 Air Cleaner Service WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. 4.4.1 Air Cleaner, 14 kW Models The engine has a replaceable high-density paper air cleaner element. See Figure 60. Cover knob Air cleaner cover Element cover nut Element cover Air cleaner base Air cleaner element 586536 Figure 60 Air Cleaner Components Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components. Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure. Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator set controller. 2. Disconnect the utility power to the generator set. 3. Disconnect the generator set engine starting battery, negative () lead first. 4. Loosen the cover retaining knob and remove the cover. 5. Remove the element cover nut, element cover, and the paper element. Note: Do not wash the paper element or clean it with pressurized air, as this will damage the element. 6. Replace the element if it is dirty, bent, or damaged. TP-7092 9/23 75 7. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary. 8. Reinstall the paper element, element cover, element cover nut, and the air cleaner cover. Secure the cover with the cover retaining knob. 9. Reconnect the utility power to the generator set. 10. Reconnect the generator set engine starting battery, negative () lead last. 4.4.2 Air Cleaner, 20/26 kW Models The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 61. Cover Knobs (qty. 2) Paper element Base tp6515 Figure 61 Air Cleaner Components Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components. Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure. Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. See Service Schedule, 20 and 26 kW Models. See Figure 61 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover. 2. Remove the paper element. 3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged. 4. When servicing the air cleaner, check the air cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components. Note: If any loose dirt or debris fell on the air cleaner base when the element was removed, carefully remove it, and wipe the base clean. Be careful that none of it drops into the intake throat. 5. Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated. 6. Install the air cleaner cover and secure with the two retaining knobs. 7. When element replacement is necessary, order genuine Kohler parts. 76 TP-7092 9/23 4.5 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See the service view section for air intake and exhaust locations. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times. Note: Do not block the generator set cooling air inlets or mount other equipment above them. Overheating and severe generator damage may occur. 4.6 Exhaust System WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 1.2 m (4 ft.) from the exhaust outlet. Periodically inspect the exhaust system components for cracks, leaks, and corrosion. · Check for corroded or broken metal parts and replace them as needed. · Check that the exhaust outlet is clear. 4.7 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. TP-7092 9/23 77 Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Never connect the negative () battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Refer to this section for general battery information and maintenance. Also consult the battery manufacturer's instructions for battery maintenance. All generator set models use a negative ground with a 12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery size and capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 62 for typical battery connections. To positive (+) terminal on starter solenoid To ground () terminal on or near starter motor EZ-273000-J Figure 62 12-Volt Engine Electrical System Single Starter Motor, Typical Battery Connection 4.7.1 Cleaning the battery Clean the battery and cables and tighten battery terminals using the service schedule recommendations. To prevent corrosion, maintain tight, dry electrical connections at the battery terminals. To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint-free cloth. After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease. 4.7.2 Checking Electrolyte Level Check the electrolyte level of batteries with filler caps monthly. Remove filler caps and verify that electrolyte level reaches bottom of filler holes. Refill as necessary with distilled water. DO NOT add fresh electrolyte. Tighten all filler caps. If water is added during freezing temperatures, run the generator set for 20- 30 minutes to mix the electrolyte and water to prevent battery damage from freezing. 78 TP-7092 9/23 4.7.3 Checking Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not have a correction table, use the correction factors in Figure 65. Determine specific gravity and electrolyte temperature of battery cells. Locate temperature in Figure 65 and adjust the specific gravity by the amount shown. The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 80°F (26.7°C). The difference between specific gravities of each cell should not exceed ±0.01. Charge the battery if the specific gravity is below 1.215 at an electrolyte temperature of 80°F (26.7°C). See Figure 63. Specific Gravity, Corrected to 80°F (26.7°C) Below 1.215 1.260 Battery Condition Needs charging Fully charged Figure 63 Specific Gravity Interpretation Some battery testers have four or five beads in a test tube. Draw electrolyte into the tube as performed with the battery hydrometer described previously. Use the manufacturer's instructions. Use Figure 64 to interpret typical test results. Number of Floating Beads 5 4 3 1 or 2 0 Battery Condition Overcharged Fully Charged A good charge A low charge A dead charge Figure 64 Bead-Type Test Interpretation Correction Example No. 1 Temperature below 26.7°C (80°F) Hydrometer Reading 1.250 Acid Temperature - 6.7°C (20°F) Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226 1.250 - .024 = 1.226 Example No. 2 Temperature above 26.7°C (80°F) Hydrometer Reading 1.235 Acid Temperature 37.8°C (100°F) Add .008 Specific Gravity Corrected Specific Gravity is 1.243 1.235 + .008 = 1.243 The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.5°C (10°F) change in temperature. 1-787 Figure 65 Specific Gravity Temperature Correction TP-7092 9/23 79 4.8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer's recommendations for storage, if available. Note: Run the generator set monthly whenever possible. 4.8.1 Lubricating System 1. Operate the generator set until it reaches operating temperature, or about 15 minutes. 2. Stop the generator set. 3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase. 4. Refill engine crankcase with oil. See the Engine Oil Recommendation section for oil recommendations. 5. Run the generator set for a few minutes to distribute the clean oil. 6. Stop the generator set. 4.8.2 Fuel System 1. Start the generator set. 2. With the generator set running, shut off the gas supply. 3. Run the generator set until the engine stops. 4. Press the OFF button on the generator set controller. 4.8.3 Cylinder Lubrication 1. Remove the spark plugs. 2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs. 3. Crank the engine two or three revolutions to lubricate the cylinders. 4.8.4 Exterior Preparation 1. Clean the exterior surface of the generator set. 2. Seal all openings in the engine with nonabsorbent adhesive tape. 3. Mask all areas to be used for electrical contact. 4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion. 4.8.5 Battery Perform battery storage last. 1. Press the OFF button on the generator set controller. 2. Disconnect the battery, negative () lead first. 3. Clean the battery. 4. Place the battery in a warm, dry location. 5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger. Follow the battery charger manufacturer's recommendations. 80 TP-7092 9/23 Section 5. Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to equipment. 5.2 Fault Messages The controller displays fault messages to aid in troubleshooting. Selected fault messages and recommended checks are listed in the Resetting the Controller After a Fault Shutdown section. Identify and correct the cause of the fault condition. Then reset the controller after a fault shutdown. See the Resetting the Controller After a Fault Shutdown section. 5.3 Circuit Protection If the generator set circuit breaker trips repeatedly, contact an authorized Kohler dealer for service. 5.3.1 Controller Internal Circuit Protection The controller is equipped with internal circuit protection. A fault message, Accy PwrOver Warning or MainPwrOverL Shutdown, is displayed if this internal protection is activated. Press OFF to reset. Contact an authorized Kohler dealer for service. 5.3.2 Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. TP-7092 9/23 81 5.4 USB Port and Auxiliary Winding Mini-Breaker The USB port is located under a small rubber cover as shown in Figure 66. The alternator winding circuit breaker is located on the engine side of the bulkhead as shown in Figure 66. A personal computer (laptop) with Kohler® SiteTechTM software can be used to view the event history and adjust controller settings. Use a USB cable with a mini-B connector to connect the controller's USB port to your PC. See TP-6701, SiteTechTM Software Operation Manual, for software operation instructions. Mini-breaker location (access through engine compartment) USB port on RDC2 controller Figure 66 USB Port and Mini-Breaker Locations 5.5 Stop Switches ADV-8928 The generator set may be equipped with an optional emergency stop switch or an engine shutdown switch. Verify that it is safe to start the generator set and apply power to the load before deactivating these switches. See the Remote Emergency Stop Switch section. 5.6 Thermostat WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative () lead first when disconnecting the battery. Reconnect the negative () lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative () lead first. Reconnect the negative () lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. 82 TP-7092 9/23 WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. The generator sets include a resettable thermostat. See Figure 67 for the thermostat location in the air intake area, near the fuel system. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the controller will display a fault (underspeed, underfrequency, or undervoltage). Check for blocked air inlets and exhaust outlets. Then follow these steps to reset the thermostat. Procedure to Reset the Thermostat 1. Disconnect the utility power to the generator by opening (turning OFF) the corresponding circuit breaker at the building's distribution panel. 2. Open the enclosure roof and secure it with the roof stay on the left side of the enclosure. 3. Remove the air intake panel. See Figure 67. 4. Press the button on the thermostat to reset it. 5. Replace the air intake panel. 6. Reconnect utility power to the generator set by closing the circuit breaker in the distribution panel. 7. Reset the fault on the controller. Refer to the Faults section for instructions, if necessary. Thermostat location Thermostat reset button Figure 67 Thermostat TP-7092 9/23 83 5.7 Troubleshooting Figure 68 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Controller display backlight is off. Controller display is off. Possible Cause Backlight turns off after about 1 minute with no activity. Low or no battery voltage. Battery weak or dead. The generator set does not crank. Battery connections reversed or poor. Emergency stop switch activated. Fault shutdown. Generator set in the OFF mode. Generator thermostat tripped. The generator set cranks but does not start, starts hard, lacks power, or operates erratically. Air cleaner clogged. Battery weak or dead. Battery connection poor. Spark plug wire connection loose. Low oil pressure shutdown. Fuel pressure insufficient. Engine malfunction. Line circuit breaker in the OFF position. Line circuit breaker tripping because of overload. No AC output. Line circuit breaker tripping because of short circuit. Auxiliary winding circuit breaker tripped. Low output or excessive drop in voltage. Generator set overloaded. Low oil pressure shutdown. No fuel. Overcrank shutdown. Auxiliary winding circuit breaker tripped. Generator set stops suddenly. Emergency stop switch activated. Fault shutdown. Generator set in the OFF mode. Figure 68 Remote stop command received from a remote switch, ATS, or OnCue® Plus. Generator thermostat tripped. Engine malfunction. General Troubleshooting Corrective Action Backlight will turn on when a button is pressed or the generator set starts. Check connections. Check generator set battery. See the Service Views section. Recharge or replace the battery. Make sure that the AC power to the generator set controller is backed up by the generator set. Check the connections. Verify that it is safe to start the engine and apply load. Then reset the stop switch or engine shutdown switch. Check the controller display for fault messages. Correct the fault condition and reset the controller. Press the RUN button to start the engine or press AUTO to allow remote starting. Check for obstructed air inlets and outlets. Reset the thermostat. Clean and/or replace the air cleaner. Recharge or replace the battery. Clean and tighten the battery connections. Check the spark plug wires. Check for oil leaks. Check the oil level and add oil if necessary. Check the fuel supply and valves. Contact an authorized Kohler dealer. Place the circuit breaker in the ON position. Reduce the load on the generator set by unplugging nonessential appliances. Contact an authorized Kohler dealer for service. Reset the circuit breaker (located in controller's service access area). Contact an authorized dealer for service if breaker trips repeatedly. Reduce the load by unplugging non-essential appliances. Check for oil leaks. Check the oil level and add oil if necessary. Check fuel valves and fuel supply. Check enclosure thermostat and reset if tripped. Check and clear air inlets and exhaust outlets. Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler dealer. Reset the auxiliary winding circuit breaker. Contact an authorized dealer for service if breaker trips repeatedly. Verify that it is safe to start the engine and apply load. Then reset the stop switch or engine shutdown switch. Check the controller display for fault messages. Correct the fault condition and reset the controller. Press the RUN button to start the engine or press AUTO to allow remote starting. Check the remote switch position. Check OnCue® Plus. Check for obstructed air inlets and outlets. Reset the thermostat. Contact an authorized Kohler dealer. 84 TP-7092 9/23 Appendix A. Abbreviations A, amp ABDC AC A/D ADC adj. ADV AGM Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. ampere after bottom dead center alternating current analog to digital advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing absorbent glass mat amp-hour anticipatory high water temperature American Iron and Steel Institute blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB anticipatory low oil pressure alternator aluminum American National Standards Institute (formerly American Standards Association, ASA) anticipatory only Air Pollution Control District CAT5 CB CC cc CCA ccw. American Petroleum Institute approximate, approximately Auxiliary Power Unit CEC cert. cfh Air Quality Management District as required, as requested as supplied, as stated, as suggested American Society of Engineers American Society of Mechanical Engineers Assembly cfm CG CID CL cm CMOS American Society for Testing Materials after top dead center automatic transfer switch Automatic auxiliary average automatic voltage regulator American Wire Gauge com coml Coml/Rec conn. cont. CPVC crit. CRM appliance wiring material Battery before bottom dead center battery charger, battery charging CSA CT Cu cUL battery charging alternator cu. in. Battery Council International cw. before dead center CWC brake horsepower cyl. black (paint color), block (engine) D/A block heater brake mean effective pressure bits per second Brass before top dead center British thermal unit British thermal units per minute Celsius, centigrade Calorie controller area network California Air Resources Board Category 5 (network cable) circuit breaker crank cycle cubic centimeter cold cranking amps Counterclockwise Canadian Electrical Code certificate, certification, certified cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) communications (port) commercial Commercial/Recreational Connection continued chlorinated polyvinyl chloride Critical Common Rail Manifold Canadian Standards Association current transformer copper Canadian Underwriter's Laboratories cubic inch Clockwise city water-cooled Cylinder digital to analog DAC dB dB(A) DC DCR DEF deg., ° dept. dia. DI/EO DIN DIP DPDT DPST DS digital to analog converter decibel decibel (A weighted) direct current direct current resistance diesel exhaust fluid degree department Diameter dual inlet/end outlet Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) dual inline package double-pole, double-throw double-pole, single-throw disconnect switch DVR digital voltage regulator E2PROM, electrically-erasable EEPROM programmable read-only memory E, emer. emergency (power source) EATS Exhaust Aftertreatment System ECM electronic control module, engine control module EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG EGSA EIA electronic governor Electrical Generating Systems Association Electronic Industries Association EI/EO end inlet/end outlet EMI emiss. eng. EPA EPS ER ES electromagnetic interference Emission Engine Environmental Protection Agency emergency power system emergency relay engineering special, engineered special ESD est. E-Stop etc. exh. ext. F FDS electrostatic discharge estimated emergency stop et cetera (and so forth) exhaust external Fahrenheit, female Fluid Dosing System TP-7092 9/23 85 FHM fl. oz. flex. freq. FS ft. ft. lb. ft./min. ftp g ga. gal. gen. genset GFI GND, flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter ground in. in. H2O in. Hg in. Lb. Inc. ind. int. int./ext. I/O IP ISO J JIS k K kA inch inches of water inches of mercury inch pounds incorporated Industrial internal internal/external input/output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo (1000) kelvin kiloampere Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m3/hr. m3/min. mA man. max. liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water level low water temperature meter, milli (1/1000) mega (106 when used with SI units), male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum gov. gph gpm gr. GRD gr. wt. H x W x D HC HCHT HD HET hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IBC IC ID IEC IEEE IMS governor gallons per hour gallons per minute grade, gross KB KBus kg kg/cm2 equipment ground gross weight height by width by depth kgm kg/m3 kHz hex cap high cylinder head temperature heavy duty high exhaust temp., high engine temp. hexagon mercury (element) kJ km kOhm, k kPa kph kV hex head kVA hex head cap horsepower hour heat shrink Housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) International Building Code integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting kVAR kW kWh kWm kWth L LAN L x W x H lb. lbm/ft3 LCB LCD LED Lph kilobyte (210 bytes) Kohler communication protocol kilogram kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz MB MCCB MCM meggar MHz mi. mil kilojoule kilometer kilo-ohm min. misc. MJ kilopascal mJ kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kilowatt-thermal liter mm mOhm, m MOhm, M MOV MPa mpg mph MS ms local area network length by width by height m/sec. mtg. pound, pounds pounds mass per cubic feet line circuit breaker liquid crystal display MTU MW mW µF light emitting diode µF liters per hour megabyte (220 bytes) molded-case circuit breaker one thousand circular mils megohmmeter megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule millijoule millimeter milliohm megohm metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren-und Turbinen-Union megawatt milliwatt microfarad microfarad 86 TP-7092 9/23 N, norm. normal (power source) PMG permanent magnet generator SCR NA not available, not applicable pot nat. gas natural gas ppm NBS National Bureau of Standards PROM NC NEC NEMA NiCd normally closed National Electrical Code National Electrical Manufacturers Association nickel cadmium psi psig pt. PTC NFPA Nm NO no., nos. National Fire Protection Association newton meter normally open number, numbers PTO PVC PVC PWM NPS NPSC NPT NPTF NR Ns OC OD OEM OF opt. OS OSHA OSHPD OV oz. National Pipe, Straight National Pipe, Straight-coupling National Standard taper pipe thread per general use National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed Occupational Safety and Health Administration Office of Statewide Health Planning and Development (California) overvoltage ounce qt. qty. R rad. RAM RDO ref. rem. Res/Co ml RFI RH RHM rly. rms rnd. RO p., pp. PC PCB pF PF page, pages personal computer printed circuit board picofarad power factor ROM rot. rpm RS RTDs ph., ø PHC PHH PHM phase Phillips® head Crimptiter (screw) Phillips® hex head (screw) pan head machine (screw) RTU RTV RW SAE PLC programmable logic control scfm potentiometer, potential parts per million s, sec. SI programmable read-only memory pounds per square inch pounds per square inch gauge pint SI/EO sil. SMTP SN positive temperature coefficient SNMP power takeoff SPDT polyvinyl chloride polyvinyl chloride pulse width modulated, pulse width modulation quart, quarts quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference Remote Residential/Commercial SPST spec specs sq. sq. cm sq. in. SMS SS std. stl. tach. TB radio frequency interference round head round head machine (screw) Relay TCP TD TDC TDEC root mean square TDEN Round read only TDES TDNE read only memory rotate, rotating revolutions per minute right side resistance temperature detectors remote terminal unit room temperature vulcanization TDOE TDON temp. term. THD TIF tol. read/write Society of Automotive Engineers standard cubic feet per minute turbo. typ. UF silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) second Systeme international d'unites, International System of Units side in/end out Silencer simple mail transfer protocol serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) square square centimeter square inch short message service stainless steel standard Steel Tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature Terminal total harmonic distortion telephone influence factor Tolerance Turbocharger typical (same in multiple locations) underfrequency TP-7092 9/23 87 UHF UIF UL UNC UNF univ. URL US UV V VAC VAR VDC VFD VGA VHF W WCR w/ WO w/o wt. xfmr ultrahigh frequency user interface Underwriter's Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer 88 TP-7092 9/23 TP-7092 9/23 89 90 TP-7092 9/23 TP-7092 9/23e Original Instructions (English) © 2018 Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com