Kohler 24RCL Operation Download Page 3

Page: 3 / 76

Table of Contents

TP-6905 9/21

Table of Contents 3

Safety Precautions and Instructions

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Introduction

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Section 1 Service Views

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Section 2 Generator Set Operation

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2.1

Operating Area

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2.2

Prestart Checklist

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2.3

Exercise the Generator Set

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2.4

Generator Set Operation

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2.4.1

Local Starting and Stopping

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2.4.2

Automatic Starting and Stopping

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2.4.3

Remote Starting and Stopping

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2.4.4

Engine Start Crank Cycle

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2.4.5

Engine Cooldown

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2.4.6

Automatic Operation with Model RXT Transfer Switch

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2.4.7

Automatic Operation with Other Transfer Switches

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2.5

Exercise

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2.5.1

Unloaded Cycle Exercise with Complete System Diagnostics

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2.5.2

Unloaded Full-Speed Exercise

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2.5.3

Loaded Full-Speed Exercise (with RXT only)

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2.5.4

Shutdown During Exercise

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2.5.5

Power Failure During Exercise

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2.5.6

Exerciser Reset

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2.5.7

Setting the Exerciser at Power-up

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2.5.8

Changing the Exercise Setting

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2.6

Faults

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2.6.1

Warnings

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2.6.2

Shutdowns

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2.6.3

ATS Communication Errors

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2.6.4

Resetting the Controller after a Fault Shutdown

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2.6.5

Status and Notice Messages

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2.6.6

Event Log

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2.7

Model RXT Transfer Switch Operation

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2.7.1

Source Availability

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2.7.2

ATS Control Sequence of Operation

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2.7.3

Time Delays

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2.7.4

ATS Load Control Relay Time Delay

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Section 3 RDC2 Controller Operation

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3.1

RDC2 Generator Set/Transfer Switch Controller

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3.2

Controls and Indicators

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3.2.1

Controller Keypad

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3.2.2

LED Indicators

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3.2.3

LCD Display

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3.3

Controller Power

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3.4

Battery Charging

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3.5

Changing Settings

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3.6

Controller Menus

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3.7

Main Menu

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3.8

Overview Menu

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3.9

Engine Metering Menu

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3.10 Generator Metering Menu

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3.11 Generator Set Information Menu

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3.12 Genset Run Time Menu

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3.13 Genset System Menu

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Summary of Contents for 24RCL

Page 1: ...Residential Light Commercial Generator Sets Models 24RCL A 30RCL A 38RCLB C Controller RDC2 TP 6905 9 21d Operation...

Page 2: ...tor Product Identification Information Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial N...

Page 3: ...ilure During Exercise 20 2 5 6 Exerciser Reset 20 2 5 7 Setting the Exerciser at Power up 20 2 5 8 Changing the Exercise Setting 21 2 6 Faults 24 2 6 1 Warnings 24 2 6 2 Shutdowns 24 2 6 3 ATS Communi...

Page 4: ...IM 53 Section 5 Scheduled Maintenance 55 5 1 General Maintenance 55 5 2 Service Schedule 57 5 3 Lubrication System 58 5 3 1 Oil Specifications 58 5 3 2 Oil Check 58 5 3 3 Oil Additions 58 5 3 4 Oil an...

Page 5: ...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...

Page 6: ...r 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...

Page 7: ...prevent inadvertent interconnection of standby and normal sources of supply WARNING Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified elec...

Page 8: ...r set is running Replace guards screens and covers before operating the generator set Hot Parts Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generat...

Page 9: ...ully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of th...

Page 10: ...KG2204 KG2204T Engine TP 6904 Parts Catalog 24RCL A 30RCL A 38RCLB C Generator Set TP 6908 User Guide OnCuer Plus Software TP 7006 Operation Installation Manual RXT ATS TP 6807 Operation Installation...

Page 11: ...Generator set master control buttons on RDC2 controller 16 Nameplate location 17 RDC2 controller 18 Fan fuses 19 Cooling air inlet remove this panel to access coolant drain 20 Access to coolant fill 2...

Page 12: ...18 See cooling system detail 19 Access to coolant fill on roof 20 Turbocharger 21 Air fuel mixer 22 Air cleaner 23 Fuel pressure regulator 24 Fuel solenoid valves located behind the fuel regulator 25...

Page 13: ...See cooling system detail 19 Access to coolant fill on roof 20 Turbocharger 21 Air fuel mixer 22 Air cleaner 23 Fuel pressure regulator 24 Fuel solenoid valves located behind the fuel regulator 25 Oil...

Page 14: ...TP 6905 9 21 14 Section 1 Service Views Notes...

Page 15: ...the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawninto a potentially occupied building through windows air intake vents or other openin...

Page 16: ...touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconn...

Page 17: ...ad 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...

Page 18: ...evel 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...

Page 19: ...cle which provides the best test of engine and alternator power backup capability Diagnostic tests at full speed can identify potential problems with the power output and alert the operator before an...

Page 20: ...t history will show Advanced Diagnostic Active The exercise schedule is maintained If the engine does not start the shutdown message will be displayed Correct the fault condition and reset the fault a...

Page 21: ...wn arrow button to step to the next Exercise menu 6 Press the Select button The setting flashes to show that it can be changed For example the hour flashes to show that the hour can be changed 7 Press...

Page 22: ...on Overview 1 2 h Engine Metering tp6810 Generator Metering Genset Information Genset Run Time Date and Time ATS Configuration Genset System Event Log Load Control PIM Status Network Information Statu...

Page 23: ...DD YY Exercise Freq Weekly Exercise Mode Unloaded Cycle Exercise Mode None Unloaded Full Sp Un loaded Cycle Loaded Full SP Contrast 50 System Freq 60 Hz System Voltage 240 V VR Voltage Adj 240 0V Syst...

Page 24: ...erator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 4 to reset the controller after a fault shutdown 2 6 3 ATS Communication Errors When a...

Page 25: ...battery voltage rises above 133 16 V of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Che...

Page 26: ...r Frequency Low Governed frequency falls below 90 of the system frequency setting for more than 10 seconds or 1 Hz below the system frequency setting for more than 60 seconds Reduce the load by turnin...

Page 27: ...of the nominal system voltage for more than 10 seconds Reduce the load by turning off appliances and restart the generator set Contact an authorized dealer for service Volts L2 L3 High Shutdwn Genera...

Page 28: ...reset due to unexpected error Backup Parameter Loaded Status Test event log command is initiated from Site Tech Default Parameters Loaded Status When the engine stops status is updated Diagnostic Exer...

Page 29: ...time HR MN event number W S I engine hours event name Press Select button at any time to return to the main menu Event codes W Warning S Shutdown I Informational Notice Figure 2 7 Event Log 2 7 Model...

Page 30: ...ions in the utility power source 2 7 4 ATS Load Control Relay Time Delay The load control time delay allows delayed starting of large motor loads such as air conditioners preventing simultaneous start...

Page 31: ...icating LEDs OFF AUTO RUN D Up Down and Select buttons for navigation through menus and adjustments D Power system indicator LEDs to show utility and generator source status and to show which source u...

Page 32: ...h menus and change settings This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller Select Up arrow Figure 3 2 Pushbutton Operation LED LED Operat...

Page 33: ...s to the controller settings See Sections 3 6 through 3 19 for menu diagrams tp6810 Genset Status Running Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure 40 psi Battery 12 3V Engine Runtime 27 4 h D...

Page 34: ...ller has been replaced D The voltage requires adjustment for a particular application D Troubleshooting generator set problems Have controller setup and adjustment performed only by an authorized Kohl...

Page 35: ...date is shown press the Select button The saved date is shown 9 Press the down arrow button to step to the next menu 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time...

Page 36: ...iew is displayed See Figure 3 7 Press the down arrow button to step to the next menu Engine Metering Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3 7 The con...

Page 37: ...Exercise 09 00p 09Dec2014 Next Maintenance 150 h or Mar2015 SW Version 4 03 Return Figure 3 8 Overview Menu 3 9 Engine Metering Menu The engine metering menu displays engine status information as sho...

Page 38: ...erviced by qualified electrical personnel DANGER The voltage calibration mode can be entered from the Generator Metering menu Contact a Kohler authorized dealer for service The Reset Calibration menu...

Page 39: ...Generator Set Information Menu 3 12 Genset Run Time Menu The data shown in Figure 3 12 are displayed No changes are allowed from this menu The Next Maintenance menu shows the number of hours of genera...

Page 40: ...adjust the voltage Fuel Type The fuel type LP or natural gas is shown Do not change the fuel type in this menu unless the generator s fuel system has been converted by an authorized dealer or service...

Page 41: ...voltage shown in these menus can be calibrated Contact an authorized dealer for service if calibration is required tp6810 Frequency 60 0 Hz Voltage L1 L2 240 V Voltage L2 L3 240 V Voltage L3 L1 240 V...

Page 42: ...es to indicate that it can be changed Press the up and down arrow buttons to change the value Press the Select button to save the value shown Use the up and down arrow buttons to move to the next valu...

Page 43: ...r systems that use the Kohlerr OnCuer Plus Home Generator Management System RBUS is a proprietary RS 485 communication protocol The Networking Information menu leads to submenus for network and RBUS c...

Page 44: ...s If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is used the IP parameters are displayed To enable or disable DHCP and change the IP settings go to t...

Page 45: ...d Note Use the OnCue password shown on the controller display for OnCue Plus applications For the initial OnCue Plus setup you will be required to reset the OnCue password on the RDC2 controller and t...

Page 46: ...includes the following optional modules D Model RXT transfer switch D Programmable Interface Module PIM D Load Shed Kit or RXT combined interface load management board tp6804 Modules Connected 3 Modul...

Page 47: ...ined interface load management board The serial numbers for the PIM and load shed kit are printed on the circuit boards inside the enclosures tp6810 Device Status Connected RD Firmware Ver ModBus ID S...

Page 48: ...ersonal computer running Kohlerr SiteTecht software is required to change the input and output settings Contact an authorized dealer for service The Kohlerr OnCuer Plus Management System can be used t...

Page 49: ...e adds and sheds loads based on the generator current The test function cycles the relays in the order of their priority For detailed information about load management operation refer to the instructi...

Page 50: ...TP 6905 9 21 50 Section 3 RDC2 Controller Operation Notes...

Page 51: ...on the generator set until it cools WARNING 4 2 Battery Heaters Battery heater kits are available to help increase the battery temperature in cold climates The battery heater kit includes a heating b...

Page 52: ...s The emergency stop E stop switch allows immediate shutdown of the generator set from a remote location The E stop assembly includes a shroud that allows the installation of a lockout tagout device t...

Page 53: ...compatible with single phase generator sets With a load management system less critical appliances can be powered by the generator set when the more important appliances are not running allowing the...

Page 54: ...TP 6905 9 21 54 Section 4 Accessories Notes...

Page 55: ...become extremely hot during operation Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and...

Page 56: ...lution 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 format...

Page 57: ...rs Hoses condition 5 6 2 X X R 3 Years or 500 hours Electrical System Battery charge 5 8 X Yearly or 120 hours Battery fluid level X Yearly or 120 hours Battery for cracks and corrosion X Yearly or 12...

Page 58: ...ll amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 5 3 4 Oil and Filter Change Accidental starting Can cause severe i...

Page 59: ...til you feel resistance Then tighten the filter an additional 3 4 turn with an oil filter wrench Torque 25 Nm 18 4 ft lbs 3 Fill with oil Use 5W 30 for oil selection and Figure 5 2 for oil capacity Mo...

Page 60: ...r 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 cleaner element Foll...

Page 61: ...bon monoxide detectors according to the manufacturer s instructions Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system CAUTION Hot...

Page 62: ...raises the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with the same rating type of cap Find the pressure cap rating in Figure 5 4 Item Rating Pres...

Page 63: ...compressed air 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 Utility power is connected to th...

Page 64: ...lug Do not bump the electrode against the cylinder head Rotate the spark plug clockwise until you feel resistance 15 Use a torque wrench to tighten each spark plug to the torque shown in Figure 5 9 Mo...

Page 65: ...nd regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Pre ignition damaged...

Page 66: ...ng 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 c...

Page 67: ...vity is below 1 215 at an electrolyte temperature of 80qF 26 7qC See Figure 5 12 Specific Gravity Corrected to 80qF 26 7qC Battery Condition Below 1 215 Needs charging 1 260 Fully charged Figure 5 12...

Page 68: ...2 Stop the generator set 3 Change the oil and oil filter see Section 5 3 4 Oil and Filter Change 4 Check the engine coolant protection see Section 5 6 Note Use antifreeze capable of withstanding the l...

Page 69: ...6 3 Fault Messages The RDC2 controller displays fault messages to aid in troubleshooting Fault messages descriptions and recommended checks are listed in Figure 2 5 Identify and correct the cause of...

Page 70: ...ntact an authorized Kohler dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on th...

Page 71: ...fy that cable size and length of run comply with the instructions in the Installation manual Low or no battery voltage Check battery connections Check generator set battery See Figure 6 1 Load managem...

Page 72: ...TP 6905 9 21 72 Section 6 Troubleshooting Notes...

Page 73: ...c inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resistance deg q de...

Page 74: ...titer screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million PROM programmable re...

Page 75: ......

Page 76: ...Kohler Co All rights reserved TP 6905 9 21d KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPo...

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Summary of Contents for 24RCL

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Kohler 24RCL, Operation, Page: 3 / 76

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Summary of Contents for 24RCL

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