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Kohler 24RCL manual

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Table of contents for the manual

  • Page 1

    Residential/Light Commercial Generator Sets Model: 24RCL Controller: RDC2 TP-6905 6 /14 Operation[...]

  • Page 2

    TP-6905 6/14 2 Engine exhaust from this pr oduct 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 t he spaces below[...]

  • Page 3

    T able of Contents TP-6905 6/14 T able of Contents 3 Product Identification Information 2 ............................................................. Safety Precautions and In structions 5 ......................................................... Introduction 9 ............................................................................... Servic[...]

  • Page 4

    T able of Contents, continued TP-6905 6/14 T able of Contents 4 3.12 Genset Run Time Menu 37 ................................................ 3.13 Genset Sys tem Menu 38 .................................................. 3.14 A TS Status Menu 39 ...................................................... 3.15 A TS Configuration Menu 40 .................[...]

  • Page 5

    TP-6905 6/14 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches , switc hgear , and access ories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent ac c[...]

  • Page 6

    TP-6905 6/14 6 Safety Precautions and Instructions metal surface away from the battery . T o avoid sparks , do not disturb the battery charger connec tions while the battery is charging. Always turn the battery charger off before disconnec ting the battery connec tions. V entilate the compartments containing batteries to prevent accumulation of exp[...]

  • Page 7

    TP-6905 6/14 7 Safety Precautions and Instructions Propane (LP) —Adequate ventilation is mandatory . Because propane is heavier than air, install propane gas detectors low in a room. Inspec t the detectors per the manufac turer ’s instructi ons. Natural Gas —Adequate ventilation is mandatory . Bec ause natural gas ris es, install natural gas [...]

  • Page 8

    TP-6905 6/14 8 Safety Precautions and Instructions Welding on the generator set. Can cause severe electri cal equipment damage. Before welding on the generator set perform the f ollowing steps: (1) Remove the battery c ables, negative ( - - ) lead first. (2) Disc onnect all engine electronic c ontrol module (ECM) connectors . (3) D isconnect all ge[...]

  • Page 9

    TP-6905 6/14 9 Introduction Introduction This manual provides operation instructions for Model 24RCL and 30RCLH residential/light commercial generator sets equipped with the RDC2 generator set/transfer switch controller . This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have t[...]

  • Page 10

    TP-6905 6/14 10 Introduction List of Related L iterature Figure 3 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set. Literature T ype Part Number Specification Sheet, 24R CL G4-228 Specification Sheet, 30R CLH G4-230 Installation Ma[...]

  • Page 11

    TP-6905 6/14 11 Service Assistance Service Assistance For professional advice on generator set power requirements and conscienti ous service, please contact your nearest authorized Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower .com. D Look [...]

  • Page 12

    TP-6905 6/14 12 Service Assistance Notes[...]

  • Page 13

    TP-6905 6/14 13 Section 1 Service Views Section 1 Service Views 6 1. Oil check (dipstick) 2. Oil fill location (on valve cover ) 3. See cooling system detail 4. Exhaust outlet 5. Enclosure locking tool (shipping location only) 6. Spark plugs 7. EPR (electronic fuel pressure regulator) 8. Engine ECM 9. Fuel inlet (1 in. NPT) 10. Fuel solenoid valves[...]

  • Page 14

    TP-6905 6/14 14 Section 1 Se rvice Views Notes[...]

  • Page 15

    TP-6905 6/14 15 Section 2 Generator Set O peration Section 2 Generator Set Operation 2.1 Operating Area Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide sym ptoms. Carbon monoxide can cause severe nausea, fain ting, or death . Carbon monoxide is a [...]

  • Page 16

    TP-6905 6/14 16 Section 2 Generator Set Operation 2.3 Exercising th e Generator Set Operate the generator set without load every week or every other week for 20 minutes. Perform all of the prestart checks before starting the exercise procedure. See Section 2.5 for instructions to set the automatic exerciser . 2.4 Generator S et Operation 2.4.1 Loca[...]

  • Page 17

    TP-6905 6/14 17 Section 2 Generator Set O peration Automatic Stop 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 stops. 2.4.7 Automatic Operation with Mod el RDT or RSB T ransfer Switches If a Kohler [...]

  • Page 18

    TP-6905 6/14 18 Section 2 Generator Set Operation D A TS connection. The controller verifies that the Model RXT A TS interface board is connected. D 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 voltag[...]

  • Page 19

    TP-6905 6/14 19 Section 2 Generator Set O peration 2. Press Select button to save the year and move to the month. 3. Use the arrow and select buttons to set the month and the day . 4. The time is displayed with the hour flashing. Use the up or down arrow key to step to the current hour and am or pm setting. Note: Check the am/pm setting displayed. [...]

  • Page 20

    TP-6905 6/14 20 Section 2 Generator Set Operation Overview - - - - > 1.2 h Engine - - - - > Metering tp6810 Generator - - - - > Metering Genset - - - -> Information Genset - - - -> Run T ime D a t e -- -- > and T ime AT S - - - - > Configuration Genset - - - -> System Event Log - - - - > Load - - - - > Control PIM - - [...]

  • Page 21

    TP-6905 6/14 21 Section 2 Generator Set O peration tp6809 Genset - - - -> System Next Exercise HR :MN PM MM/DD/YY Exercise Freq: Weekly/Every Other Week Meas. System: English < - - - - Return Next Exercise * HR:MN PM MM/DD/YY Exercise Freq: Weekly Exercise Mode: Unloaded Cycle Exercise Mode: None/Unloaded Full Sp/ Unloaded Cycle/Loaded Full S[...]

  • Page 22

    TP-6905 6/14 22 Section 2 Generator Set Operation 2.6 Faults Selected fault conditions are shown in Figure 2-5. Fault conditions are classified as warnings or shutdowns. If a fault occurs that is not listed in the table, contact an authorized distributor/dealer for service. Note: All ECM faults are grouped under one listing in Figure 2-5. If a prog[...]

  • Page 23

    TP-6905 6/14 23 Section 2 Generator Set O peration Fault (RDC2) Fault (OnCue r Plus) Condition Check AC Sens Loss Wa r n i n g (1 sec.) Shutdwn (3 sec.) AC Sensing Lost AC Sensing Lost. In Auto mode, generator output AC sens ing is lost. Detec tion begins 10 seconds after crank disc onnect. W arning: after 1 second if no output detec ted after cran[...]

  • Page 24

    TP-6905 6/14 24 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check CoolT empHigh Wa r n i n g Ect Higher Than Expected 1 Coolant temperature is too high. Check c oolant level. Check radiator and fans for obstruction. Contact an authorized distributor/dealer for serv ice and provide the fault code. CoolT emp Vhi Shut[...]

  • Page 25

    TP-6905 6/14 25 Section 2 Generator Set O peration Fault (RDC2) Fault (OnCue r Plus) Condition Check Frequency High Shutdwn High Frequency Governed frequency exceeds 1 10% of the system’s fr equency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine s tart (10 sec ond inhibit). Contact an authorized distributor/dea[...]

  • Page 26

    TP-6905 6/14 26 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check Over Crank Shutdwn Over Crank Three unsucces sful starting attempts . Check the fuel supply , spark plug, and battery . Check f or loose connec tions. Contact an authorized distributor/dealer for serv ice. PrimLoopOpn Wa r n i n g Primary Loop Open I[...]

  • Page 27

    TP-6905 6/14 27 Section 2 Generator Set O peration 2.6.5 Event Log The event log displays up to 1000 controller faults and notices, starting with the mo st 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 e[...]

  • Page 28

    TP-6905 6/14 28 Section 2 Generator Set Operation 2.7.2 A TS Control Seque nce of Operation See Figure 2-8 for time delay settings. Normal Source Fails: 1. The load control contact opens. 2. The engine start time delay times out. 3. The generator set is signaled to start. 4. The generator starts and the emergency source becomes available. 5. The no[...]

  • Page 29

    TP-6905 6/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set / T ransfer Switch Controller Model 24RCL and 30RCLH generator sets are equipped with the RDC2 generator set/transfer switch controller . The RDC2 contr ols the following power system components: D Model 24RCL or 30RCLH generator set D Mod[...]

  • Page 30

    TP-6905 6/14 30 Section 3 RDC2 Controller Operation 3.2.1 Cont roller Keypad The Run, Of f, and Auto buttons control the generator set as described in Figure 3-2. Use the Select, Up arrow , and Down arrow buttons to navigate through the menus and change settings, if necessary . See Section 2.4 for operation instructions. 3.2.2 LED Indicato rs LEDs [...]

  • Page 31

    TP-6905 6/14 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit liquid crystal diode (LCD) display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-4. When the system is in AUTO, the LCD display[...]

  • Page 32

    TP-6905 6/14 32 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 battery and the utility power to the generator set. If controller power is disconnected and reconnected, you wi[...]

  • Page 33

    TP-6905 6/14 33 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 3-7. 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[...]

  • Page 34

    TP-6905 6/14 34 Section 3 RDC2 Controller Operation 3.6 Controller Menus The following sections show the RDC2 controller menus and submenus. Use the Select button and the up and down arrow buttons to navigate the menus as shown in the diagrams. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can ena[...]

  • Page 35

    TP-6905 6/14 35 Section 3 RDC2 Controller Operation 3.8 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6809 Genset Status Standby V oltage: 240V Freq: 60.0Hz Engine: 95F Oil: 40 PSI Battery 12.3V Engine Runtime: 27.4 h Date: 02DEC2014 T ime: HR:MNpm Next Exercise: 09:00p 09Dec2014 Next Maintenance: 150 h or Mar2015 SW V ersion: 4[...]

  • Page 36

    TP-6905 6/14 36 Section 3 RDC2 Controller Operation 3.10 Gen erator Metering M enu The generator metering menu displays the generator voltage and frequency . See Figure 3-10. The voltage calibration mode can be entered from the generator metering menu. V oltage Calibration Hazardous voltag e. Will cause severe inju ry or death. This equipment mus t[...]

  • Page 37

    TP-6905 6/14 37 Section 3 RDC2 Controller Operation 3.1 1 Generator Set Info rmation Menu The generator set model number and serial numbers are displayed. No changes are allowed f rom 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[...]

  • Page 38

    TP-6905 6/14 38 Section 3 RDC2 Controller Operation 3.13 Gen set System Menu The genset system menu displays the system information shown in Figure 3-13. 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 genera[...]

  • Page 39

    TP-6905 6/14 39 Section 3 RDC2 Controller Operation 3.14 A T S Status M enu 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 Mode[...]

  • Page 40

    TP-6905 6/14 40 Section 3 RDC2 Controller Operation 3.15 A TS Configura tion 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 settings and time delays, and change the settings, if necessary . Changing A TS Configuration S[...]

  • Page 41

    TP-6905 6/14 41 Section 3 RDC2 Controller Operation 3.16 Date an d Time 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 3-16. tp6810 Date: 02Dec2014 Ti m e : 12:34pm T ime Format: 12hr|24hr Date and Ti m e < - - - - Return [...]

  • Page 42

    TP-6905 6/14 42 Section 3 RDC2 Controller Operation 3.17 Netwo rking Informatio n Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or LCM, and for systems that use the Kohler r OnCue r Plus Generator Management System. RBUS is a proprietary RS-485 communication protocol. The[...]

  • Page 43

    TP-6905 6/14 43 Section 3 RDC2 Controller Operation 3.17.1 Networking Status Submen u The Networking Status submenu contains settings for OnCue r Plus. See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if[...]

  • Page 44

    TP-6905 6/14 44 Section 3 RDC2 Controller Operation 3.17.2 Networking Configu ration Submenu (OnCu e Plus Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue r Plus Generator Management System. For most applications, DHCP is enabled and the IP settings cannot be changed from the controller ke[...]

  • Page 45

    TP-6905 6/14 45 Section 3 RDC2 Controller Operation 3.17.3 RBUS Information Submenu 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) [...]

  • Page 46

    TP-6905 6/14 46 Section 3 RDC2 Controller Operation 3.17.4 Remote Devices Submen u 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) tp6810 Device Sta tus: Connected RD Firmware V er.: ### ModBus ID: ## S/N: ######### <<*D[...]

  • Page 47

    TP-6905 6/14 47 Section 3 RDC2 Controller Operation 3.18 Pro grammab le Interface Module (PIM) Menus The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This is a status display menu only . Input and output settings cannot be changed from the RDC2 controller ’s user interface. A pers[...]

  • Page 48

    TP-6905 6/14 48 Section 3 RDC2 Controller Operation 3.19 Load Control Me nus The generator set may be connected to a Load Control Module (LCM) or a Model RXT transfer switch equipped with a Load Shed kit. The Load Control menu displays the status of the load control inputs and outputs, and allows a test of the load control output relays. Generator [...]

  • Page 49

    TP-6905 6/14 49 Section 4 Scheduled Maintenance Section 4 Scheduled Maintenance 4.1 General Mainten ance Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery . Reconnect t he negative ( - - ) lead last when [...]

  • Page 50

    TP-6905 6/14 50 Section 4 Scheduled Maintenance The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair , or operate the generator set. H[...]

  • Page 51

    TP-6905 6/14 51 Section 4 Scheduled Maintenance 4.2 Service Schedule System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est General Maintenance Fluid leaks X Daily Engine oil level X Daily Coolant level 4.6.1 X Daily Obstructions or combustible materials near exhaust outlet X Weekly Leaks, hissing, a[...]

  • Page 52

    TP-6905 6/14 52 Section 4 Scheduled Maintenance 4.3 Lubrication System 4.3.1 Oil Specifications Use oil that displays the American Petroleum Institute (API) Starburst certification mark FOR GASOLINE ENGINES on the container . Do not use straight-weight oils recommended for industrial or stationary engines. CC or CD classification oils, even when la[...]

  • Page 53

    TP-6905 6/14 53 Section 4 Scheduled Maintenance 2. Replace the oil filter . a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench. Note: On model 30RCLH only , ensure that the oil cooler adapter nut is tightened to specification [T orque = 40 Nm (29.5 ft.lbs.)] and that oil cooler adapter and gasket are seated properly [...]

  • Page 54

    TP-6905 6/14 54 Section 4 Scheduled Maintenance 4.4 Air Cleaner At the interval specified in the service schedule (Section 4.2), inspect and clean or replace the air cleaner element. Clean the element more frequently in dirty , dusty conditions. Check the element for accumulated oil or dirt that could cause poor performance. Replace a damaged air c[...]

  • Page 55

    TP-6905 6/14 55 Section 4 Scheduled Maintenance Carbon monoxide dete ctors. Carbon monoxide can cause severe nausea, fainting, or death. Inst all carbon monoxide detectors on eac h level of the building. Locate the detectors to adequately w arn the building’s occupants of t he presence of c arbon monoxide. Keep the detectors operational at all ti[...]

  • Page 56

    TP-6905 6/14 56 Section 4 Scheduled Maintenance 4.6.2 Cooling System Inspectio n T o prevent generator shut down or damage because of overheating: D Keep the cooling air inlets clean and unobstructed D Inspect the radiator ’s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator f[...]

  • Page 57

    TP-6905 6/14 57 Section 4 Scheduled Maintenance 4.7 Ignition System Airborne particles. Can cause severe injur y or blind - ness. Wear protective goggles and c lothing when using pow er tools, hand tools , or comp ressed a ir . W ARNING Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the gene[...]

  • Page 58

    TP-6905 6/14 58 Section 4 Scheduled Maintenance Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark plug Built-up deposits and gap between elec trodes closing. Oil or carbon fouling. Clean and regap the s park plug. Oil-fouled spark plug Wet, black deposits on t he insulator shell, bore, and electrodes. Excess ive oi[...]

  • Page 59

    TP-6905 6/14 59 Section 4 Scheduled Maintenance 4.8 Battery Consult the battery manufacturer ’s instructions regarding battery care and maintenance. Sulfuric acid in batteries. Can cause severe i njury or death. Wear protective goggles and clothing. Battery acid may c ause blindness and burn s kin. W ARNING Battery electrolyte is a dilute d sulfu[...]

  • Page 60

    TP-6905 6/14 60 Section 4 Scheduled Maintenance 4.9 Storage Proced ure Hazardous voltag e. Will cause severe inju ry or death. Disconnec t all power sourc es before opening the enclosure. DANGER Connecting the battery and the battery c harger . Hazardous voltage can cau se severe injury or death. Reconnect the battery c orrectly , positive to pos i[...]

  • Page 61

    TP-6905 6/14 61 Section 5 Troubleshooting Section 5 T roubleshooting 5.1 Introduc tion 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 b reaker . The charts include a list of common problems, possible [...]

  • Page 62

    TP-6905 6/14 62 Section 5 Tr oubleshooting 5.5 Generator Set T roubleshooting Figure 5-1 contains generator set troubleshooting, diagnos tic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corr ective Action The generator set does not crank. Battery weak or dead. Recharge or replac e the battery .[...]

  • Page 63

    TP-6905 6/14 63 Section 5 Troubleshooting 5.6 Controller T roubles hooting Figure 5-2 contains basic troubleshootin g information for the RDC2 controller . Problem Possible Cause Corr ective Action Controller LCD d i s p l a yi so f f . Low or no battery v oltage. Chec k connections . Check generator s et battery . See Figure 5-1. Controller displa[...]

  • Page 64

    TP-6905 6/14 64 Section 5 Tr oubleshooting Notes[...]

  • Page 65

    TP-6905 6/14 Appendix 65 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[...]

  • Page 66

    TP-6905 6/14 66 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[...]

  • Page 67

    [...]

  • Page 68

    E 2014 by Kohler Co. All rights reserved. TP -6905 6/14 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 au thorized installation, service, and sales dealer in the US and Canada:[...]