6 Generator Spec.pdf

Residential/Commercial Generator Sets

Models:

14/20RESA

14/20RESAL

20RESC

20RESCL

Controllers:

RDC2

DC2

TP-6804 6/15j

Operation

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

California Proposition 65

Kohler strongly recommends that only factory-authorized distributors or 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

Accessory Number Accessory Description

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

Table of Contents

TP-6804 6/15 Table of Contents

Product Identification Information 2

Safety Precautions and Instructions 7

Introduction 11

Service Assistance 13

Section 1 Descriptions and Service Views 15

1.1 Introduction 15

1.2 Engine 15

1.3 Alternator 15

1.4 Generator Set Enclosure 15

1.5 Transfer Switch 15

1.6 Controllers 15

1.7 Accessories 18

1.7.1 Carburetor Heater 18

1.7.2 Fuel Regulator Heater (20kW models only) 18

1.7.3 OnCue Plus Generator Management System 18

1.7.4 Programmable Interface Module (PIM) 18

1.7.5 Load Management 18

1.7.6 Concrete Mounting Pads 19

1.7.7 Emergency Stop Kit 19

1.7.8 Battery Heater Kit 19

1.8 Service Views 20

Section 2 Generator Set Operation 21

2.1 Prestart Checklist 21

2.2 Exercising the Generator Set 21

2.3 Generator Set Operation 21

2.3.1 Local Starting and Stopping 22

2.3.2 Automatic Operation 22

2.3.3 Remote Starting and Stopping 22

2.3.4 Engine Start Crank Cycle 22

2.3.5 Engine Cooldown 22

2.3.6 Automatic Operation with Model RXT Transfer Switch 22

2.3.7 Automatic Operation with Other Transfer Switches 22

2.4 Exercise 23

2.4.1 Setting the Exerciser 23

2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics 23

2.4.3 Unloaded Full-Speed Exercise 24

2.4.4 Loaded Full-Speed Exercise (with RXT only) 24

2.4.5 Power Failure During Exercise Cycle 24

2.5 Faults 25

2.5.1 Warnings 25

2.5.2 Shutdowns 25

2.5.3 ATS Communication Errors 25

2.5.4 Resetting the Controller after a Fault Shutdown 25

2.5.5 Faults Related to Paralleling 28

Section 3 RDC2 Controller Operation 31

3.1 RDC2 Generator Set/Transfer Switch Controller 31

3.2 Controls and Indicators 31

3.2.1 Controller Keypad 32

3.2.2 LED Indicators 32

3.2.3 LCD Display 33

3.3 Controller Power 34

3.4 Battery Charging 34

Table of Contents, continued

TP-6804 6/15Table 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

3.7 RDC2 Controller Menus 38

3.8 Main Menu 38

3.9 Overview Menu 40

3.10 Engine Metering Menu 40

3.11 Generator Metering Menu 41

3.12 Generator Set Information Menu 42

3.13 Genset Run Time Menu 42

3.14 Genset System Menu 43

3.15 ATS Status Menu 44

3.16 ATS Configuration Menu 45

3.17 Date and Time Menu 46

3.18 Networking Information Menus 46

3.18.1 Networking Status Submenu 47

3.18.2 Networking Configuration Submenu (OnCue Password) 48

3.18.3 RBUS Information 50

3.18.4 Remote Devices Submenu 51

3.19 Programmable Interface Module (PIM) Status Menu 52

3.20 Load Control Menus 53

3.21 Event Log 54

Section 4 DC2 Controller Operation 55

4.1 DC2 Generator Set/ Transfer Switch Controller 55

4.2 Controls and Indicators 55

4.2.1 Controller Keypad 56

4.2.2 LED Indicators 56

4.2.3 LCD Display 57

4.3 Controller Power 57

4.4 Battery Charging 57

4.5 Exercise 58

4.5.1 Exercise Modes 58

4.5.2 Setting the Exerciser 58

4.5.3 Exerciser Reset 58

4.6 Event Log 58

4.7 Maintenance Timer 59

4.8 OnCue Password 59

Section 5 Scheduled Maintenance 61

5.1 Scheduled Maintenance 61

5.1.1 Service Schedule, 14 kW Models 62

5.1.2 Service Schedule, 20 kW Models 63

5.2 Lubrication System 64

5.2.1 Low Oil Pressure Shutdown 64

5.2.2 Oil Check 64

5.2.3 Engine Oil Recommendation 64

5.2.4 Oil Change Procedure 65

5.2.5 Resetting the Maintenance Timer 66

5.2.6 Oil Cooler (20RESA/RESAL only) 66

5.3 Spark Plugs 66

5.4 Air Cleaner Service 67

5.4.1 Air Cleaner, 14 kW Models 67

5.4.2 Air Cleaner, 20 kW Models 68

5.5 Cooling System 69

Table of Contents, continued

TP-6804 6/15 Table of Contents

5.6 Exhaust System 69

5.7 Fuel Regulator Vent Tubes 69

5.8 Battery 70

5.8.1 Cleaning the Battery 70

5.8.2 Checking Electrolyte Level 70

5.8.3 Checking Specific Gravity 71

5.9 Storage Procedure 72

5.9.1 Lubricating System 72

5.9.2 Fuel System 72

5.9.3 Cylinder Lubrication 72

5.9.4 Exterior Preparation 72

5.9.5 Battery 72

Section 6 Troubleshooting 73

6.1 Introduction 73

6.2 Fault Messages 73

6.3 Circuit Protection 73

6.3.1 Controller Internal Circuit Protection 73

6.3.2 Line Circuit Breaker 73

6.4 USB Port and Auxiliary Winding Mini-Breaker 73

6.5 Thermostat 74

6.6 Troubleshooting 75

Appendix A Abbreviations 77

TP-6804 6/156

Notes

TP-6804 6/15 7Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY 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.

Thismanual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, orsubstantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

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

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.

WARNING

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.

Battery

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.

WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acid cancause 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 immediatemedical 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.

TP-6804 6/158 Safety Precautions and Instructions

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 thebattery. 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.

Engine Backfire/Flash Fire

Risk of fire.

Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

WARNING

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

Servicing the fuel system. A flash fire cancausesevere injuryor 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.

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

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

WARNING

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 fumeswhenworking 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.

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. Carbonmonoxide 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:

D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D 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 improvewithinminutes of breathing fresh air.

TP-6804 6/15 9Safety Precautions and Instructions

Fuel System

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

WARNING

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 causedby vibration. Donot 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 (10--14 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

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

CAUTION

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.

Hazardous Voltage/ Moving Parts

Hazardous voltage.

Will cause severe injury or death.

This equipment must be installed and serviced by qualified electrical personnel.

DANGER

Hazardous voltage.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Moving parts.

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.

WARNING

Welding the generator set.

Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

CAUTION

Grounding electrical equipment.

Hazardous voltage can 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, transfer switch, and related equipment and electrical circuits. Turn off themain 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.

TP-6804 6/1510 Safety Precautions and Instructions

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 can 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 can 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.

Heavy Equipment

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.

WARNING

Hot Parts

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

WARNING

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

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.

TP-6804 6/15 11Introduction

Introduction

This manual provides operation and maintenance instructions for residential/commercial model 14/20RESA/RESAL and 20RESC/RESCL generator sets equipped with Kohler RDC2 or DC2 generator set/transfer switch controllers. See Figure 1.

Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator.

Have the generator set installed by an authorized distributor/dealer or service technician. Refer to the Installation Manual for installation instructions.

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. Readand 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 andperform requiredserviceat theprescribed intervals.

Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.

Figure 1 Generator Set

List of Related Literature Figure 2 identifies literature available for the generator sets covered in this manual and related accessories.

Only trained and qualified personnel should install or service the generator set.

Generator Set Literature Part Number

Installation Manual, Generator Set TP-6803

Service Manual, Generator Set TP-6805

Transfer Switch Literature

Operation/Installation Manual, Model RXT Automatic Transfer Switch TP-6807

Operation/Installation Manual, Model RDT Automatic Transfer Switch TP-6345

Accessory Literature

Operation Manual, OnCuer Plus TP-6928

Operation Manual, SiteTecht Software TP-6701

Installation Instructions, Load Shed Kit TT-1609

Installation Instructions, Programmable Interface Module (PIM) TT-1584

Installation Instructions, PowerSyncr Automatic Paralleling Module (APM) TT-1596

Figure 2 Related Literature

TP-6804 6/1512 Introduction

Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from thenameplate into thespacesprovided 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

Service Duty

Voltage

Alt Model

Insulation

MFG Date

Amps

Phase

RPM

Battery

Fuel kW kVA

PF

Hz

Genset Model

Spec Number

Serial Number

Material Number

Emission Information The Kohlerr Model CH740 engine used on the 14RESA/RESAL generator set is certified to operate using natural gas or propane fuel.

The Kohlerr Model CH1000 engine used on the 20RESA/RESAL and 20RESC/RESCL 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 EmissionControl orAir Index label indicates thenumber of operating hours for which the engine has been shown tomeet CARB or EPA emission requirements. Figure 3 provides the engine compliance period (in hours) associated with the category descriptor, which may be found on the certification label.

Emission Compliance Period

EPA

Category C 250 hours

Category B 500 hours

Category A 1000 hours

CARB

Moderate 125 hours

Intermediate 250 hours

Extended 500 hours

Figure 3 Emission Compliance Period

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH740 engines (14RESA/RESAL) is EM for U.S. EPA, California, and Europe.

The exhaust emission control system for the CH1000 engine (20RESA/RESAL and 20RESC/RESCL) is EM for U.S. EPA, California, and Europe.

Generator Set Application

Kohlerr Power Systems (KPS) ensures that all Kohlerr generator sets are certified to applicable standards for their intended application. It is the owner/operator’s responsibility to operate Kohlerr generator sets exclusively according to the directions provided in the accompanying operation manuals.

Kohlerr 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.

The US Clean Air Act explicitly prohibits using Emergency Standby generators 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. The U.S. Clean Air Act authorizes owner/operator fines of up to $3,750 per day of operation in violation of the generator set’s certification.

Owners/operators should familiarize themselves with and perform all testing, maintenance, notification, reporting and record keeping as required by the Clean Air Act. In most cases, performance testing is not required if the generator is operated and maintained according to the operation manual. However, owners/operators must retain maintenance records.

TP-6804 6/15 13Service Assistance

Service Assistance

For professional advice on generator set power requirementsandconscientiousservice, pleasecontact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading Generators—Electric.

D Visit the Kohler Power Systems website at KOHLERPower.com.

D Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regional office.

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems Netherlands B.V.

Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone: (31) 168 331630 Fax: (31) 168 331631

Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455

China North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231 Fax: (91) 80 3315972

Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

TP-6804 6/1514 Service Assistance

TP-6804 6/15 15Section 1 Descriptions and Service Views

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 servicemanual, engineoperationmanual, and engine servicemanual for additional specifications.

Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/ dealer.

1.2 Engine

The generator set has a four-cycle, twin cylinder, air-cooled Kohlerr engine. The engine operates on clean-burning natural gas or LPG. Engine features include:

D Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliability under all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of parts subjected to the most wear and tear.

D Field-convertible multi-fuel systems that allow fuel changeover fromnatural gas to LPG(andvice- versa) while maintaining emissions certification.

D Digital spark advance optimizes ignition timing for the selected fuel.

1.3 Alternator

The generator uses Kohler’s unique PowerBoostt voltage regulation system, which provides instant response to load changes.

PowerBoostt ensures reliable motor starting and consistent voltage levels. PowerBoostt 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 exclusive engineered composite enclosure that is corrosion-proof, even in harsh seaside environments, and impact-resistant, even in cold weather. 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 1/4 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 and DC2 controllers are designed to interface with and control the Kohler Model RXT Automatic Transfer Switch (ATS). Do not use theKohler Model RRT transfer switch with the RDC2 or DC2 controller.

If the power system uses a different model transfer switch, theRDC2andDC2controllerswill not control the transfer switch. An ATS other than theModel RXTmust be equippedwith a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set.

1.6 Controllers

RESA and RESC models are equipped with the RDC2 controller. RESAL and RESCL models use the DC2 controller. See Figure 1-1.

The controller provides integrated control for the generator set, Kohlerr 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.

RDC2 (RESA/RESC) DC2 (RESAL/RESCL)

Figure 1-1 Generator Set Controllers

TP-6804 6/1516 Section 1 Descriptions and Service Views

RDC2 Controller Features

D Six-button keypad d OFF, AUTO, and RUN pushbuttons d Select and arrow buttons for access to system configuration and adjustment menus

D LED indicators for OFF, AUTO, and RUN modes

D LED indicators for utility power and generator set source availability and ATS position (Model RXT transfer switch required)

D LCD display d Two lines x 16 characters per line d Backlit display with adjustable contrast for excellent visibility in all lighting conditions

D Scrolling system status display d Generator set status d Voltage and frequency d Engine temperature d Oil pressure d Battery voltage d Engine runtime hours

D Date and time displays

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintain steady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load to full-load

D Automatic start with programmed cranking cycle

D Programmable exerciser can be set to start automatically on any future day and time, and run every week or every two weeks

D Exercise modes d Unloaded weekly exercise with complete system diagnostics d Unloaded full-speed exercise d Loaded full-speed exercise (Model RXT ATS required)

D Front-access mini USB connector for Kohlerr SiteTecht connection

D Integral Ethernet connector for the Kohlerr OnCuer Plus Generator Management System

D Built-in battery charger

D Remote two-wire start/stop capability for connection of Model RDT or other transfer switches

D Diagnostic messages d Displays diagnostic messages for the engine, generator, Model RXT transfer switch, programmable interface module (PIM), and load management device d Over 70 diagnostic messages can be displayed

D Maintenance reminders

D System settings d System voltage, frequency, and phase d Voltage adjustment d Measurement system, English or metric

D ATS status (Model RXT ATS required) d Source availability d ATS position (normal/utility or emergency/generator) d Source voltage and frequency

D ATS control (Model RXT ATS required) d Source voltage and frequency settings d Engine start time delay d Transfer time delays d Voltage calibration d Fixed pickup and dropout settings

D Programmable Interface Module (PIM) status displays d Input status (active/inactive) d Output status (active/inactive)

D Load control menus d Load status d Test function

TP-6804 6/15 17Section 1 Descriptions and Service Views

DC2 Controller Features

D Four-button keypad: OFF, AUTO, RUN, and EXERCISE pushbuttons

D LED indicators for OFF, AUTO, and RUN modes

D LCD display:

d Two lines x 16 characters per line d Backlit display with adjustable contrast for excellent visibility

D Scrolling system status display d Generator set status d Voltage and frequency d Engine temperature d Oil pressure d Battery voltage d Engine runtime hours d Maintenance reminders d OnCuer status (connected/disconnected)

D Date and time displays

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintain steady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load to full-load

D Automatic start with programmed cranking cycle

D Exercise modes d Unloaded weekly exercise with complete system diagnostics d Unloaded full-speed exercise d Loaded full-speed exercise (Model RXT ATS required)

D Front-access mini USB connector for SiteTecht connection

D Integral Ethernet connector for KohlerrOnCuerPlus

D Built-in 2.5 amp battery charger

D Remote two-wire start/stop capability for connection of Model RDT or other transfer switches

D Diagnostic messages d Displays diagnostic messages for the engine, generator set, model RXT transfer switch, and optional programmable interface module (PIM) and load management device d Over 70 diagnostic messages can be displayed

D A laptop computer and Kohlerr SiteTecht software can be used to change system settings or upgrade controller firmware.

TP-6804 6/1518 Section 1 Descriptions and Service Views

1.7 Accessories

The following optional accessories are offered for the 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 (32_F). The carburetor heater preventscondensationandcarburetor icing. The heater requires a continuous source of AC power.

See the generator set Installation manual for more information.

1.7.2 Fuel Regulator Heater (20kW

models only)

An optional fuel regulator heater for the 20RESA/20RESAL and 20RESC/RESCL is recommended 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.

See the generator set Installation manual for more information.

1.7.3 OnCue Plus Generator

Management System

The Kohlerr OnCuer Plus Generator Management System allowsmonitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device.

OnCuer Plus can be configured to send email or text message notifications in the event of a generator set fault.

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.

1.7.4 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 RDC2or DC2 controller, and can also be controlled remotely using OnCue Plus.

ThePIM ismounted inaNEMA3Raluminumenclosure, which can be mounted indoors or outdoors. See the installation instructions provided with the PIM.

1.7.5 Load Management

Two optional load management devices are available for use with single-phase generator sets and a model RXT or RDT transfer switch.

D The optional Load Shed Kit mounts inside a model RDT or RXT transfer switch.

D The combined interface/ load management board is available for the Model RXT transfer switch.

The load management devices provide an automatic load management system to comply with Section 702.5 of NEC 2008. 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 RDC2or DC2 controller. The load on the generator set ismonitored, 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-6804 6/15 19Section 1 Descriptions and Service Views

1.7.6 Concrete Mounting Pads

Kohler offers optional concrete mounting pads that are custom-designed for Model 14RESA/RESAL, 20RESA/RESAL, and 20RESC/RESCL generator sets.

Three-inch and four-inch thick pads are available.

Four-inch pads are recommended for storm-prone areas.

1.7.7 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.

1.7.8 Battery Heater Kit

The battery heater kit includes a thermostatically-controlled battery heating wrap to warm the battery in cold weather. Battery heater kits are recommended for generator installed in regions where the temperature regularly falls below 0_C (32_F).

TP-6804 6/1520 Section 1 Descriptions and Service Views

1.8 Service Views

12 13

ADV-8424

ADV-8754

1. Hinged inner cover

2. Hinged roof

3. Air intake

4. Lifting holes

5. Lock

6. Enclosure key, provided with generator set

7. Exhaust outlet

8. Oil check (dipstick)

9. Oil fill

10. Oil drain valve

11. Thermostat (20RESC/20RESCL models only)

12. Muffler

13. Air cleaner

14. Oil filter

15. Line circuit breaker

16. USB connector (for firmware updates)

17. RDC2 or DC2 controller

18. Field-connection terminal block (behind panel)

19. Fuel block or fuel jet location (inside hose fitting)

20. Digital spark advance ignition (DSAI) leads, general location

21. Fuel solenoid valve

22. Fuel regulator assembly

23. AC receptacles for optional carburetor heater (not shown)

24. Engine starting battery location (battery purchased separately)

25. Oil drain hose

26. Nameplate location

27. Oil drain valve

28. Optional emergency stop button location

29. High voltage electrical in

30. Low voltage electrical in

31. Fuel inlet

ENCLOSURE PANELS

REMOVED TO SHOW DETAIL

BACK DETAIL

114 10

Figure 1-2 Service Views (20 kW model shown)

TP-6804 6/15 21Section 2 Generator Set Operation

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.

D Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections.

D Check for corrodedor brokenmetal parts and replace them as needed.

D Check that the exhaust outlet is unobstructed.

Oil Level. Check the oil level before starting the generator set and at the intervals given in Section 5, Scheduled Maintenance. 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 Section 2.4 for information about loaded and unloaded exercise modes. For instructions to set the exerciser, see:

D Section 3.6 for the RDC2 controller

D Section 4.5 for the DC2 controller

2.3 Generator Set Operation

Hazardous voltage.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Moving parts.

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

WARNING

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 throughwindows, air intake vents, or other openings.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbonmonoxide 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:

D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D 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-6804 6/1522 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 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.

SeeSections 2.3.6 and 2.3.7 formore 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 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 Section 2.5.

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.

2.3.5 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 5minutes. 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 theModel 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.

2.3.6 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.

2.3.7 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 ATSmust 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.

TP-6804 6/15 23Section 2 Generator Set Operation

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.

Automatic Stop

The engine start contacts on the ATS open to signal the generator set to stop.

2.4 Exercise

TheRDC2 or DC2 controller can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly or every two weeks is required to keep the engine and alternator in good operating condition.

Three exercise modes are available: unloaded cycle, unloaded full speed, and loaded full speed. See Sections 2.4.2 through 2.4.4 for information about the exercise modes. 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 theModel 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 providedwith 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, and then to set the exerciser.

The first settingwill flash. Press theUp andDownarrow buttons to change the setting. Press Select to save the setting and move on to the next. See Section 3.5 for more detailed instructions to change settings on the RDC2. SeeSection 3.6 formore detailed instructions to set the exerciser or change the exercise settings.

The DC2 controller does not prompt you to set the exerciser. See Section 4.5 for instructions to set the exerciser on the DC2.

2.4.2 Unloaded Cycle Exercise with

Complete System Diagnostics

An unloaded exercise runs the generator set without signalling 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 2-1 and described below.

D Runs at reduced speed for 10 minutes to warm up and exercise the engine.

D 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 problemswith the power output and alert the operator before an emergency event.

D Ramps down and runs at reduced speed for 5 minutes to cool down theenginebefore shuttingdown automatically.

E ng in e S pe ed ,R

P M

Engine Exercise

Full-Speed Diagnostics

Cooldown

3 min.

1 min.

1 min.

10 min. 5 min.

Figure 2-1 Unloaded Exercise Cycle

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.

D ATS connection. The controller verifies that the Model RXT ATS 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

TP-6804 6/1524 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 full speed. An overspeed or underspeed condition will result in a fault condition and shutdown.

D Generator output frequency and voltage.

Operating the generator at full speed allows the RDC2/DC2 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.

D Oil pressure. Oil pressure is verified to ensure proper lubrication of critical engine components.

Pressure is monitored at both reduced and full speeds. If theoil pressure is low, theLowOilPressure message is displayed and the generator set shuts down.

2.4.3 Unloaded Full-Speed Exercise

Theunloaded full-speedexercise runs thegenerator set at full speed…