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Kohler 60RCL manual

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Table of contents for the manual

  • Page 1

    Residential/Light Commercial Generator Sets Model: 38RCL 48RCL 60RCL Controller: RDC2 TP-6810 1 1/13b Operation[...]

  • Page 2

    TP-6810 1 1/13 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 Propositi on 65 Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in t he spaces be[...]

  • Page 3

    T able of Contents TP-6810 1 1/13 T able of Contents 3 Product Identification Information 2 ............................................................. Safety Precautions and Instructions 5 ......................................................... Introduction 9 ............................................................................... Servi[...]

  • Page 4

    T able of Contents, continued TP-6810 1 1/13 T able of Contents 4 3.12 Genset Run Time Menu 35 ................................................ 3.13 Genset Sys tem Menu 36 .................................................. 3.14 A TS Status Menu 37 ...................................................... 3.15 A TS Configuration Menu 38 ...............[...]

  • Page 5

    TP-6810 1 1/13 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPORT 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 acc[...]

  • Page 6

    TP-6810 1 1/13 6 Safety Precautions and Instructions metal surface away from the battery . T o avoid sparks , do not dist urb the battery charger connec tions w hile 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[...]

  • Page 7

    TP-6810 1 1/13 7 Safety Precautions and Instructions Explosive fuel vapors can cause severe injury or death. Ta k e additional precautions when us ing the following fuels: 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[...]

  • Page 8

    TP-6810 1 1/13 8 Safety Precautions and Instructions Engine block heater . Hazardous voltage can cause severe injury or death. The engine block heater c an cause el ectrica l shock. Remo ve the engine block heater plug from the electrical outlet before w orking on the block heater elec trical connections . Electrical backfeed to the utility . Hazar[...]

  • Page 9

    TP-6810 1 1/13 9 Introduction Introduction This manual provides operation instructions for Model 38RCL, 48RCL, and 60RCL 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 sourc[...]

  • Page 10

    TP-6810 1 1/13 10 Introduction List of Related Literature 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, 38R CL G4-214 Specification Sheet, 48R CL G4-21 1 Specification [...]

  • Page 11

    TP-6810 1 1/13 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 Loo[...]

  • Page 12

    TP-6810 1 1/13 12 Service Assistance Notes[...]

  • Page 13

    TP-6810 1 1/13 13 Section 1 Service Views Section 1 Service Views 1. Nameplate location 2. Engine ECM and EPR (electr onic fuel pressure regulator) 3. Oil check (dipstick) 4. See cooling system detail 5. Exhaust outlet 6. Enclosure locking tool (shipping location only) 7. Spark plugs 8. Block heater connection valve 9. Block heater (optional) 10. F[...]

  • Page 14

    TP-6810 1 1/13 14 Section 1 Service Views 1. Air cleaner 2. Nameplate location 3. Oil check (dipstick) 4. Engine ECM and EPR (electr onic fuel pressure regulator) 5. See cooling system detail 6. Exhaust outlet 7. Enclosure locking tool (shipping location only) 8. Spark plugs 9. Block heater connection valve 10. Block heater (optional) 1 1. Fuel inl[...]

  • Page 15

    TP-6810 1 1/13 15 Section 2 Generator Set O peration Section 2 Generator Set Operation 2.1 Operating Area Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a po[...]

  • Page 16

    TP-6810 1 1/13 16 Section 2 Generator Set Operation 2.3 Exercising the Generator Set Operate the generator set without load every week or every other week for 20 minutes. Perform all of t he prestart checks before starting the exercise procedure. See Section 2.5 for instructions to set the automatic exerciser . 2.4 Generator Set Operation 2.4.1 Loc[...]

  • Page 17

    TP-6810 1 1/13 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 Mo del RDT or RSB T ransfer Switches If a Kohle[...]

  • Page 18

    TP-6810 1 1/13 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 volt[...]

  • Page 19

    TP-6810 1 1/13 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-6810 1 1/13 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-6810 1 1/13 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/Unloade d Full Sp/ Unloaded Cycl e/Loaded F[...]

  • Page 22

    TP-6810 1 1/13 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. If a programmable interface module (PIM) is connected to the generator se[...]

  • Page 23

    TP-6810 1 1/13 23 Section 2 Generator Set O peration Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition Check AC Sens Lost W( 1s e c . ) SD (3 sec.) AC Sensing Lost. In Auto mode, generator output AC sens ing is lost. Starts 10 s econds after crank disc onnect. W arning: after 1 second if no output detec ted after crank disc onnect. Shutdown: aft[...]

  • Page 24

    TP-6810 1 1/13 24 Section 2 Generator Set Operation Fault Wa r n i n g ( W ) o r Shutdown (SD) Condition Check Exer Not Sch W Exercis e Not Scheduled. N o exercis e has been scheduled on the RDC2 controller. See Section 2.5 for inst ructions to s et the exerciser . Generator Frequency High SD Governed frequency exceeds 1 10% of the system’s fr eq[...]

  • Page 25

    TP-6810 1 1/13 25 Section 2 Generator Set O peration 2.6.5 Event Lo g 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 th[...]

  • Page 26

    TP-6810 1 1/13 26 Section 2 Generator Set Operation 2.7.2 A TS Control Sequence of Operation See Figure 2-8 for time delay settings. Preferred 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. Th[...]

  • Page 27

    TP-6810 1 1/13 27 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Gener ator Set / T r ansfer Switch Contro ller Model 38 RCL, 48RCL, and 60RCL generator sets are equipped with the RDC2 generator set/transfer switch controller . The RDC2 controls the following power system components: D Model 38RCL, 48RCL, or 60RCL [...]

  • Page 28

    TP-6810 1 1/13 28 Section 3 RDC2 Controller Operation 3.2.1 Con troller 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 Ind icators LED[...]

  • Page 29

    TP-6810 1 1/13 29 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 displ[...]

  • Page 30

    TP-6810 1 1/13 30 Section 3 RDC2 Controller Operation 3.3 Control ler 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[...]

  • Page 31

    TP-6810 1 1/13 31 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[...]

  • Page 32

    TP-6810 1 1/13 32 Section 3 RDC2 Controller Operation 3.6 Contr oller 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 [...]

  • Page 33

    TP-6810 1 1/13 33 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: 02DEC201 1 T ime: HR:MNpm Next Exercise: 09:00p 09Dec201 1 Next Maintenance: 150 h or Mar2012 SW V ersio[...]

  • Page 34

    TP-6810 1 1/13 34 Section 3 RDC2 Controller Operation 3.10 Generator Metering Menu 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 voltage. Will cause severe injury or death. This equipment mus t b[...]

  • Page 35

    TP-6810 1 1/13 35 Section 3 RDC2 Controller Operation 3.1 1 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[...]

  • Page 36

    TP-6810 1 1/13 36 Section 3 RDC2 Controller Operation 3.13 Genset 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 gener[...]

  • Page 37

    TP-6810 1 1/13 37 Section 3 RDC2 Controller Operation 3.14 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 Mode[...]

  • Page 38

    TP-6810 1 1/13 38 Section 3 RDC2 Controller Operation 3.15 A TS Configur ation 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[...]

  • Page 39

    TP-6810 1 1/13 39 Section 3 RDC2 Controller Operation 3.16 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 3-16. tp6810 Date: 02Dec201 1 Ti m e : 12:34pm T ime Format: 12hr|24hr Date and Ti m e < - - - - Retu[...]

  • Page 40

    TP-6810 1 1/13 40 Section 3 RDC2 Controller Operation 3.17 Networking Information 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 Home Generator Management System. RBUS is a proprietary RS-485 communication protocol. The[...]

  • Page 41

    TP-6810 1 1/13 41 Section 3 RDC2 Controller Operation 3.17.1 Networking Status Submen u The Networking Status submenu contains settings for OnCue r . See the OnCue Software Operation Manual for information about the appropriate network settings for OnCue. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP[...]

  • Page 42

    TP-6810 1 1/13 42 Section 3 RDC2 Controller Operation 3.17.2 Networking Configu ration Submenu (On Cue Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue r Home Generator Management System. For most applications, DHCP is enabled and the IP settings cannot be changed from the controller keypa[...]

  • Page 43

    TP-6810 1 1/13 43 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 44

    TP-6810 1 1/13 44 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 .: 122 ModBus ID: 12 S/N: XXXXXXXXX <<[...]

  • Page 45

    TP-6810 1 1/13 45 Section 3 RDC2 Controller Operation 3.18 Programmable 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 46

    TP-6810 1 1/13 46 Section 3 RDC2 Controller Operation 3.19 Load Control Menus 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 47

    TP-6810 1 1/13 47 Section 4 Scheduled Maintenance Section 4 Scheduled Maintenance 4.1 General Maintenance Accidental starting. Can cause severe injury 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 48

    TP-6810 1 1/13 48 Section 4 Scheduled Maintenance 4.2 Service Schedule Perform maintenance on each item in the service schedule at t he designated intervals for the life of the generator set. Operation Daily Every 100 Hr . Every 150 Hr . Every 400 Hr . Every 1000 Hr . Every 1500 Hr . Every 2000 Hr . As Req’d GENERAL MAINTENANCE Check for fluid le[...]

  • Page 49

    TP-6810 1 1/13 49 Section 4 Scheduled Maintenance 4.3 Lubr ication 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[...]

  • Page 50

    TP-6810 1 1/13 50 Section 4 Scheduled Maintenance d. Install the new oil filter following the instructions provided with the filter . 3. Fill with oil. See Figure 4-1 for oil selection and Figure 4-3 for oil capacity . Model Oil Capacity , L (qt.) 38RCL, 48RC L, and 60RCL 4.7 (5.0) Figure 4-3 Oil Capacity 4. Check for leaks. a. Press the OFF button[...]

  • Page 51

    TP-6810 1 1/13 51 Section 4 Scheduled Maintenance 4.5 Exhaust System Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each lev el of the bui[...]

  • Page 52

    TP-6810 1 1/13 52 Section 4 Scheduled Maintenance 4.6.2 Coolin g System Inspection 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[...]

  • Page 53

    TP-6810 1 1/13 53 Section 4 Scheduled Maintenance 4.7 Ignition System Service the spark plugs at the interval specified in the service schedule using the following procedure. 1. Press the OFF button on the RDC2 controller . 2. Disconnect the power to the battery charger . 3. Disconnect the generator set engine starting battery , negative ( - - ) le[...]

  • Page 54

    TP-6810 1 1/13 54 Section 4 Scheduled Maintenance 10. Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap. See Figure 4-10. Position the side electrode directly over the center electrode. 1-51 1 Figure 4-10 Spark Plug Gap Adjustment 1 1. Reinstall the spark plug. Do not bump the[...]

  • Page 55

    TP-6810 1 1/13 55 Section 4 Scheduled Maintenance Battery short circuits. Explosion can cause severe injury or death. Short circ uits can cause bodily injury and/or equipment damage. Disc onnect the battery before generator set installation or maintenanc e. Remove all jewelry before servicing t he equipment. Us e tools with insulated handles. Remov[...]

  • Page 56

    TP-6810 1 1/13 56 Section 4 Scheduled Maintenance Notes[...]

  • Page 57

    TP-6810 1 1/13 57 Section 5 Troubleshooting Section 5 T roubleshooting 5.1 Introducti on 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[...]

  • Page 58

    TP-6810 1 1/13 58 Section 5 Troubleshooting 5.5 G enerator 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 Corrective Action The generator set does not crank. Battery weak or dead. Rec harge or replace the battery [...]

  • Page 59

    TP-6810 1 1/13 59 Section 5 Troubleshooting 5.6 Contr oller T roubleshooti ng Figure 5-2 contains basic troubleshootin g information for the RDC2 controller . Problem Possible Cause Corrective Action Controller LCD d i s p l a yi so f f . Low or no battery v oltage. Check connec tions. Check generator s et battery . See Figure 5-1. Controller displ[...]

  • Page 60

    TP-6810 1 1/13 60 Section 5 Troubleshooting Notes[...]

  • Page 61

    TP-6810 1 1/13 Appendix 61 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 [...]

  • Page 62

    TP-6810 1 1/13 62 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 k ilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowat[...]

  • Page 63

    [...]

  • Page 64

    E 2012, 2013 by Kohler Co. All rights reserved. TP-6810 1 1/13b 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 [...]