Kohler RDC2 Operation Download Page 3

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Table of Contents

TP-7102 3/20

Table of Contents 3

Product Identification Information

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Safety Precautions and Instructions

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Introduction

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Service Assistance

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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

Exercising 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

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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Summary of Contents for RDC2

Page 1: ...Residential Light Commercial Generator Sets Model 48RCLB 60RCLA Controller RDC2 TP 7102 3 20c Operation...

Page 2: ...on 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 Gene...

Page 3: ...d Exercise with RXT only 19 2 5 4 Shutdown During Exercise 19 2 5 5 Power Failure During Exercise 19 2 5 6 Exerciser Reset 20 2 5 7 Setting the Exerciser at Power up 20 2 5 8 Changing the Exercise Set...

Page 4: ...n System 52 4 3 1 Oil Specifications 52 4 3 2 Oil Check 52 4 3 3 Oil Additions 52 4 3 4 Oil and Filter Change 52 4 4 Air Cleaner 54 4 5 Exhaust System 55 4 6 Cooling System 56 4 6 1 Checking and Filli...

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: ...hort 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...

Page 7: ...pment Hazardous voltage will cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the ge...

Page 8: ...e cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Fill system before starting unit WARNING Hot engine and exhaust system Can cause severe injury or dea...

Page 9: ...to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for...

Page 10: ...TP 7101 Operation Manual Engine TP 7095 Parts Catalog Engine TP 6731 Parts Catalog Generator Set TP 6812 Accessory Literature Part Number Installation Instructions Block Heaters TT 1587 Installation...

Page 11: ...office Headquarters Europe Middle East Africa EMEA Kohler EMEA Headquarters Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Kohler...

Page 12: ...TP 7102 3 20 12 Service Assistance Notes...

Page 13: ...access 15 Customer connection access panel 16 Line circuit breaker 17 Generator set master control buttons on RDC2 controller 18 RDC2 controller 19 Air cleaner 20 Cooling air inlet remove this panel t...

Page 14: ...TP 7102 3 20 14 Section 1 Service Views Notes...

Page 15: ...ator set where exhaust gas could seep inside or be drawninto a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause seve...

Page 16: ...accumulation of explosive gases Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof saf...

Page 17: ...el of any building near the generator set Oil Level Maintain the oil level at or near not over the full mark on the dipstick 2 3 Exercising the Generator Set Operate the generator set every week or ev...

Page 18: ...rce 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 w...

Page 19: ...e exercise does not start D Coolant level check The coolant level is checked D Communication integrity tests J1939 RBUS Ethernet and USB are monitored for messages indicating that the controller and w...

Page 20: ...age and set the date time and exercise schedule 1 At power up you will be prompted to select a language for the controller displays Use the up and down arrow buttons to step through the language optio...

Page 21: ...l RXT transfer switch the exercise can be changed to a loaded exercise Set the Exercise Mode to loaded full speed unloaded full speed or unloaded cycle as shown in Figure 2 3 12 Set the exercise frequ...

Page 22: ...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 23: ...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 Model RXT transfer switch is used an...

Page 24: ...ltage High W Engine starting battery voltage rises above 125 of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to...

Page 25: ...0 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service Lo Crank Vlt W Low cranking voltage Battery voltage falls below 60 of system battery voltag...

Page 26: ...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 6 Event Log 2 7 Model RXT Tran...

Page 27: ...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 starting...

Page 28: ...TP 7102 3 20 28 Section 2 Generator Set Operation Notes...

Page 29: ...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 utility or genera...

Page 30: ...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 31: ...e 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 Date 02J...

Page 32: ...een 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 Kohler distrib...

Page 33: ...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 34: ...view 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 co...

Page 35: ...Exercise 09 00p 09Mar2018 Next Maintenance 150 h or Jan2019 SW Version 1 01 Return Figure 3 8 Overview Menu 3 9 Engine Metering Menu The engine metering menu displays engine status information as sho...

Page 36: ...tering menu Contact a Kohler authorized distributor dealer for service The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration if necessary See Fi...

Page 37: ...3 11 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...

Page 38: ...Manual for instructions to 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 au...

Page 39: ...hown in these menus can be calibrated Contact an authorized distributor or 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...

Page 40: ...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 41: ...at controller power up To change the date time or time format 12 hour or 24 hour use the Date and Time menu See Figure 3 16 tp6810 Date 02Feb2018 Time 12 34pm Time Format 12hr 24hr Date and Time Retur...

Page 42: ...PIM or load management device and for systems that use the Kohlerr OnCuer Plus Home Generator Management System The Networking Information menu leads to submenus for network and RBUS communication set...

Page 43: ...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 the Networking Configura...

Page 44: ...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 then en...

Page 45: ...ludes 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 Module T...

Page 46: ...rface load management board The serial numbers for the PIM and load shed kit are printed on the circuit boards tp6810 Device Status Connected RD Firmware Ver 1 01 ModBus ID 12 S N XXXXXXXXX DeviceType...

Page 47: ...ter running Kohlerr SiteTecht software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohlerr OnCuer Plus Generator Management System c...

Page 48: ...ice 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 TT 1609 pro...

Page 49: ...ts The engine and exhaust system components become extremely hot during operation Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter arm...

Page 50: ...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 t...

Page 51: ...See Section 4 8 Tighten control and power wiring connections Check the DEPR fuel pressure Engine Operation Manual Check the drive belt for cracks splitting or breaks Engine Operation Manual Yearly or...

Page 52: ...funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 4 3 4 Oil and Filter Change Accidental starting Can cause severe injury or death Disconnect...

Page 53: ...tions 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 48RCLB and 60RCLA 4 7 5 0 Figure 4 3 Oil Capacity 4 Check for le...

Page 54: ...kfire can cause severe injury or death Do not operate the generator set with the air cleaner removed At the interval specified in the service schedule inspect and clean or replace the air cleaner elem...

Page 55: ...ed persons does not improve within minutes of breathing fresh air Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of...

Page 56: ...overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not mix long life coolant and conventional coolants Do not use alcohol or methanol...

Page 57: ...es 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...

Page 58: ...to or farther from the center electrode to set the correct gap See Figure 4 9 Position the side electrode directly over the center electrode 1 511 Figure 4 9 Spark Plug Gap Adjustment 11 Reinstall the...

Page 59: ...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 sp...

Page 60: ...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 contain...

Page 61: ...avity is below 1 215 at an electrolyte temperature of 80 F 26 7 C See Figure 4 12 Specific Gravity Corrected to 80 F 26 7 C Battery Condition Below 1 215 Needs charging 1 260 Fully charged Figure 4 12...

Page 62: ...4 Oil and Filter Change 4 Check the engine coolant protection see Section 4 6 Note Use antifreeze capable of withstanding the lowest possible temperatures 5 Keep spark plugs in their holes or seal spa...

Page 63: ...ormation 5 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 c...

Page 64: ...ct an authorized Kohler distributor 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 l...

Page 65: ...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 5 1 Load managem...

Page 66: ...TP 7102 3 20 66 Section 5 Troubleshooting Notes...

Page 67: ...s cu in cubic 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 resista...

Page 68: ...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 69: ...TP 7102 3 20 69 Notes...

Page 70: ...TP 7102 3 20 70 Notes...

Page 71: ......

Page 72: ...Kohler Co All rights reserved TP 7102 3 20c 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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