Kohler 20RESAL-SA7 manual

Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL Controllers: RDC2 DC2 TP-6804 1/15h Operation[...]

Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately afte[...]

T able of Contents TP-6804 1/15 T able of Contents Product Identification Information 2 ............................................................. Safety Precautions and Instru ctions 7 ......................................................... Introduction 11 ............................................................................... Service[...]

T able of Contents, continued TP-6804 1/15 T able of Contents 3.5 Changing Settings 34 ..................................................... 3.6 Setting the Exerciser 36 ................................................... 3.6.1 Setting the Exerciser at Controller Power-up 36 ...................... 3.6.2 Changing the Exercise Settings 36 ...........[...]

T able of Contents, continued TP-6804 1/15 T able of Contents 5.5 Cooling System 69 ....................................................... 5.6 Exhaust System 69 ....................................................... 5.7 Fuel Regulator V ent T ubes 69 .............................................. 5.8 Battery 70 ...................................[...]

TP-6804 1/15 6 Notes[...]

TP-6804 1/15 7 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T ANT 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. T o prevent acciden[...]

TP-6804 1/15 8 Safety Precautions and Instructions Battery gases. Explo sion can cause severe injury or d eath. 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. T o prevent burns and sparks that could cause an e[...]

TP-6804 1/15 9 Safety Precautions and Instructions Fuel System Explosive fuel vapors. Can cause severe inju ry or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe in jury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels.[...]

TP-6804 1/15 10 Safety Precautions and Instructions Welding on the generator set. Can cause severe electrical equi pment 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 generato[...]

TP-6804 1/15 11 Introduction Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA and 14/20RESAL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1. The RDC2 and DC2 controllers control the generator set and the optional Model RXT tra[...]

TP-6804 1/15 12 Introduction 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 in Section 1.8 for the nameplate location. GM12070[...]

TP-6804 1/15 13 Service Assistance Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric. D Visit t he Kohler Power Systems website at KOHLERPower .com. D Look at the labe[...]

TP-6804 1/15 14 Service Assistance Notes[...]

TP-6804 1/15 15 Section 1 Descriptions and Service V iews 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 serv[...]

TP-6804 1/15 16 Section 1 Descriptions and Service Views RDC2 (RESA) DC2 (RESAL) Figure 1-2 Revised (red - - board) Controllers RDC2 Controller Features D Six-button keypad d OFF , AUT O, and RUN pushbuttons d Select and arrow buttons for access to system configuration and adjustment menus D LED indicators for OFF , AUT O, and RUN modes D LED indic[...]

TP-6804 1/15 17 Section 1 Descriptions and Service V iews D Programmable Interface Module (PIM) status displays d Input status (active/inactive) d Output status (active/inactive) D Load control module (LCM) menus d Load status d T est function DC2 Controller Features D Four-button keypad: OFF , AUTO, RUN, and EXERCISE pushbuttons D LED indicators f[...]

TP-6804 1/15 18 Section 1 Descriptions and Service Views 1.7 Accessories The following optional accessories are off ered for the RESAand RESAL generator sets. 1.7.1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 _ C( 3 2 _ F). The carburetor heater p[...]

TP-6804 1/15 19 Section 1 Descriptions and Service V iews 1.8 Service Views 17 20 21 1 3 10 11 16 19 ADV -8424 13 12 22 1. Hinged inner cover 2. Hinged roof 3. Air intake 4. Lock 5. Locking tool, provided with generator set 6. Exhaust outlet 7. Oil check (dipstick) 8. Oil fill 9. Lifting holes 10. Muffler 1 1. Air cleaner 12. Oil filter 13. Line ci[...]

TP-6804 1/15 20 Section 1 Descriptions and Service Views Notes[...]

TP-6804 1/15 21 Section 2 Generator Set Operation Section 2 Generator Set Operation 2.1 Prestart Checklist T o 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 [...]

TP-6804 1/15 22 Section 2 Generator Set Operation 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 mon[...]

TP-6804 1/15 23 Section 2 Generator Set Operation Press the AUTO button to put the controller into automatic mode. Automatic Start The engine start contacts on the A TS close to signal the generator set to start, and remain closed while the generator set is running. Automatic Stop The engine start contacts on the A TS open to signal the generator s[...]

TP-6804 1/15 24 Section 2 Generator Set Operation the controller detects low battery voltage, the condition is indicated on the display . D Communication integrity tests. J1939, RBUS, Ethernet, and USB are monitored for messages indicating that the controller and wiring are reliable. D Engine speed. Engine speed is measured at reduced speed and ful[...]

TP-6804 1/15 25 Section 2 Generator Set Operation 2.5 Faults The RDC2 or DC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in Figure 2-3. Contact an authorized distributor/dealer for service, if necessary . 2.5.1 W arnings The controller displays a fault message but the generator set [...]

TP-6804 1/15 26 Section 2 Generator Set Operation Fault Message Wa r n i n g ( W ) o r Shutdown (SD) Condition Check AC Sens Loss W( 1s e c . ) SD (3 sec.) * AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect. W arning: after 1 second if no output detected after crank disconnect. Sh[...]

TP-6804 1/15 27 Section 2 Generator Set Operation Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition Check Frequency Low SD * 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 se[...]

TP-6804 1/15 28 Section 2 Generator Set Operation 2.5.5 Faults Related to Paralleling If the PowerSync Automatic Paralleling Module (APM) is used with two 14RESA or two 20RESA 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 ev[...]

TP-6804 1/15 29 Section 2 Generator Set Operation Fault T ext Description Possible Causes * ErraticSig The power metering on this controller gives a signal that is not consistent with t he system configuration. Reversing the power direction does not resolve the problem. Bad wiring to the CT . T oo much tension on wires from the CT to the controller[...]

TP-6804 1/15 30 Section 2 Generator Set Operation Notes[...]

TP-6804 1/15 31 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ T ransfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller . See Figure 3-1 for controller illustrations. The operation is the same for the original and revised controllers. M[...]

TP-6804 1/15 32 Section 3 RDC2 Controller Operation 3.2.1 Controller Keypad The RUN, OFF , and AUT O buttons control the generator set as described in Figure 3-3. Use the Select, Up arrow , and Down arrow buttons to navigate through the menus and change settings, if necessary . See Section 2.3 for operation instructions. 3.2.2 LED Indicators LEDs a[...]

TP-6804 1/15 33 Section 3 RDC2 Controller 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 3-5. When the system is in AUTO, t he screens shown in Figure 3-6 a[...]

TP-6804 1/15 34 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the utility power to the generator set and disconnect the battery . If controller power is disconnected and reconne[...]

TP-6804 1/15 35 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and T ime menu. 4. T o change the date and time settings, press the Select b[...]

TP-6804 1/15 36 Section 3 RDC2 Controller Operation 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[...]

TP-6804 1/15 37 Section 3 RDC2 Controller Operation tp6804 System Freq: XX.X Hz Genset - - - - > System System V olt System Battery HOLD: Next Exercise HR :MN PM MM/DD/YY HOLD: Exercise Freq: Weekly/Bi-Weekly System Phase Language: < - - - - Return Next Exercise * HR:MN PM MM/DD/YY Exercise Freq: Weekly Exercise Mode: Loaded HOLD: Exercise Mo[...]

TP-6804 1/15 38 Section 3 RDC2 Controller Operation 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 [...]

TP-6804 1/15 39 Section 3 RDC2 Controller Operation Overview - - - - > 1.2 h Engine - - - - > Metering tp6804 Generator - - - - > Metering Genset - - - - > Information Genset - - - - > Run T ime D a t e -- -- > and T ime AT S - - - - > Configuration * Genset - - - - > System Event Log - - - - > Load - - - - > Control ][...]

TP-6804 1/15 40 Section 3 RDC2 Controller Operation 3.9 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6804 Genset Status Standby V oltage: 240V Freq: 60.0Hz Engine: 72F Oil Pressure: OK Battery 12.0V Engine Runtime: 24.5 h Date: 02DEC201 1 T ime: HR:MNpm Next Exercise: 09:00p 09Dec201 1 Next Maintenance: 150 h or Mar2012 SW V er[...]

TP-6804 1/15 41 Section 3 RDC2 Controller Operation 3.1 1 Generator Metering Menu The generator metering menu displays the generator voltage and frequency . See Figure 3-12. V oltage Calibration Hazardous voltage. Will cause severe injury o r death. This equipment must be installed and serviced by qualified electrical personnel. DANGER The voltage [...]

TP-6804 1/15 42 Section 3 RDC2 Controller Operation 3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed. 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 co[...]

TP-6804 1/15 43 Section 3 RDC2 Controller Operation 3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can adjust these settings, if necessary . If the generat[...]

TP-6804 1/15 44 Section 3 RDC2 Controller Operation 3.15 A TS Status Menu A TS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model A TS is connected to the engine start connections, Remote A TS is displayed on the A TS Status screen. The A TS Status menu displays Model [...]

TP-6804 1/15 45 Section 3 RDC2 Controller Operation 3.16 A TS Configuration Menu Note: The A TS Configuration menu appears only if a Model RXT transfer switch is connected. Use the A TS Configuration submenu to check the Model RXT transfer switch system setti ngs and time delays, and change the settings, if necessary . Changing A TS Configuration S[...]

TP-6804 1/15 46 Section 3 RDC2 Controller Operation 3.17 Date and T ime Menu The date and time will typically be set at controller power - - up. T o change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18. 3.18 Networking Information Menus Use the networking menus to view and adjust communication sett[...]

TP-6804 1/15 47 Section 3 RDC2 Controller Operation 3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue r . 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. T o[...]

TP-6804 1/15 48 Section 3 RDC2 Controller Operation 3.18.2 Networking Configuration Submenu (OnCue Password) The Networking Configuration menu includes settings used for communication with the Kohler OnCue r Plus Generator Management System. Password Note: Use the OnCue password shown on the controller display for OnCue or OnCue Plus applications. [...]

TP-6804 1/15 49 Section 3 RDC2 Controller Operation DNS 2: 123.456.789.123 tp6804 < - - - - Return DHCP: Enabled Reset OnCue Password Reset OnCue Password? No S/N: 1234567 New PW: 12345 Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. Networking Configuration HOLD Reset OnCue Password? Y es UP[...]

TP-6804 1/15 50 Section 3 RDC2 Controller Operation 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: D Model RXT transfer switch D Programmable Interface Module (PIM) D Load Control Module (LCM) or load [...]

TP-6804 1/15 51 Section 3 RDC2 Controller Operation 3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT A TS D Programmable Interface Module (PIM) D Load Control Module (LCM) or load shed kit The serial numbers for the PIM, LCM, and load shed kit are printed on the circu[...]

TP-6804 1/15 52 Section 3 RDC2 Controller Operation 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 fr[...]

TP-6804 1/15 53 Section 3 RDC2 Controller Operation 3.20 Load Control Menus The Load Control menu displays the status of the Load Control Module (LCM) or load shed kit inputs and outputs, and allows a test of the load control output relays. This menu appears only if an LCM, load shed kit, or Model RXT transfer switch with the combined interface/ lo[...]

TP-6804 1/15 54 Section 3 RDC2 Controller Operation 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 ev[...]

TP-6804 1/15 55 Section 4 DC2 Controller Operation Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ T ransfer Switch Controller Model RESAL generator sets are equipped with the DC2 generator set/transfer switch controller . Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller . See Section 3 for RDC[...]

TP-6804 1/15 56 Section 4 DC2 Controller Operation 4.2.1 Controller Keypad The RUN, OFF , and AUT O buttons control the generator set as described in Figure 4-3. Use the EXERCISE button to set the exerciser on the DC2 controller . See Section 4.5 for instructions to set the exerciser . Note: A personal computer (laptop) with Kohler r SiteT ech t so[...]

TP-6804 1/15 57 Section 4 DC2 Controller Operation 4.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator set is running, the messages shown in Figure 4-5 are displayed. When the system is in AUTO, the LCD display steps through the status messages shown in Fig[...]

TP-6804 1/15 58 Section 4 DC2 Controller Operation 4.5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly is required to keep the engine and alternator in good operating condition. A laptop computer with Kohler r SiteT ech t software can be used to ch[...]

TP-6804 1/15 59 Section 4 DC2 Controller Operation 4.7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set. Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Sec[...]

TP-6804 1/15 60 Section 4 DC2 Controller Operation Notes[...]

TP-6804 1/15 61 Section 5 Scheduled Maintenance Section 5 Scheduled Maintenance Accidental starting. Can cause severe inju ry 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 . W [...]

TP-6804 1/15 62 Section 5 Scheduled Maintenance 5.1.1 Service Schedule, 14RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quarterly Main tank supply level X W eekly Fuel piping X Y early Lubrication 5.2 Oil level X X 8 hours or before u[...]

TP-6804 1/15 63 Section 5 Scheduled Maintenance 5.1.2 Service Schedule, 20RESA/RESAL Models System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Fuel regulator vent tubes, if equipped X X Y early[...]

TP-6804 1/15 64 Section 5 Scheduled Maintenance 5.2 Lubrication System See the service schedules in Section 5.1 for oil change and oil filter replacement intervals. See the service views in Section 1.8 for the oil drain, oil c heck, oil fill, and oil filter locations. Accidental starting. Can cause severe inju ry or death. Disconnect the battery ca[...]

TP-6804 1/15 65 Section 5 Scheduled Maintenance 5.2.4 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. [...]

TP-6804 1/15 66 Section 5 Scheduled Maintenance 5.2.5 Resetting the Maintenance Timer 14/20RESA (RDC2): 1. From the Overview menu, step down to t he Genset Run T ime 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 T imer? Y es” is d[...]

TP-6804 1/15 67 Section 5 Scheduled Maintenance Generator Set Model Spark Plug Gap 14RESA/RESAL 0.76 mm (0.030 in.) Figure 5-4 Spark Plug Gap 1- -514 Figure 5-5 Checking the Spark Plug Gap 1- -51 1 Figure 5-6 Adjusting the Spark Plug Gap 5.4 Air Cleaner Service Fire. Can cause severe inju ry or death. Do not smoke or permit flames or sparks near fu[...]

TP-6804 1/15 68 Section 5 Scheduled Maintenance 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 [...]

TP-6804 1/15 69 Section 5 Scheduled Maintenance Air Cleaner Service Replace the paper element at the intervals indicated in the service schedule. See Section 5.1.2 for the service schedule. See Figure 5-8 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 pa[...]

TP-6804 1/15 70 Section 5 Scheduled Maintenance 5.8 Battery Sulfuric acid in batteries. Can cause severe inju ry or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Battery electrolyte is a dilute d sulfuric acid. Battery acid can cause severe inju ry or death. Battery acid can cause blindness an[...]

TP-6804 1/15 71 Section 5 Scheduled Maintenance 5.8.3 Checking Specific Gravity Use a battery hydrometer to c heck 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 use[...]

TP-6804 1/15 72 Section 5 Scheduled Maintenance 5.9 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. 5.9.1 Lubricating System 1. Op[...]

TP-6804 1/15 73 Section 6 T roubleshooting Section 6 T roubleshooting 6.1 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 c[...]

TP-6804 1/15 74 Section 6 T roubleshooting 1. USB port 1 GM90304 Figure 6-2 Revised Controller USB Port Location 1 1. Alternate mini-breaker location (access through air intake area) Figure 6-3 Auxiliary Winding Mini-Breaker Location[...]

TP-6804 1/15 75 Section 6 T roubleshooting 6.5 T roubleshooting Figure 6-4 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity . Backlight[...]

TP-6804 1/15 76 Section 6 T roubleshooting Notes[...]

TP-6804 1/15 Appendix 77 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing Ah amp-hour AH[...]

TP-6804 1/15 78 Appendix kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k  kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-t[...]

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E 201 1, 2012, 2013, 2014, 2015 by Kohler Co. All rights reserved. TP-6804 1/15h KOHLER CO . Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales deal[...]