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TP-6880 10/14

14 Section 1 Descriptions and Service Views

RDC2 Controller Features

Six-button keypad

OFF, AUTO, and RUN pushbuttons

Select and arrow buttons for access to system

configuration and adjustment menus

LED indicators for OFF, AUTO, and RUN modes

LED indicators for utility power and generator set

source availability and ATS position (Model RXT

transfer switch required)

LCD display

Two lines x 16 characters per line

Backlit display with adjustable contrast for

excellent visibility in all lighting conditions

Scrolling system status display

Generator set status

Voltage and frequency

Engine temperature

Oil pressure

Battery voltage

Engine runtime hours

Date and time displays

Smart engine cooldown senses engine temperature

Digital

isochronous

governor

maintain

steady-state speed at all loads

Digital voltage regulation:

0.5% RMS no-load to

full-load

Automatic start with programmed cranking cycle

Programmable exerciser can be set to start

automatically on any future day and time, and run

every week or every two weeks

Exercise modes

Unloaded weekly exercise with complete system

diagnostics

Unloaded full-speed exercise

Loaded full-speed exercise (Model RXT ATS

required)

Front-access mini USB connector for SiteTech

connection or the Kohler USB utility

Integral Ethernet connector for Kohler

OnCue

Plus

Built-in 2.5 amp battery charger

Remote two-wire start/stop capability for optional

connection of Model RDT or RSB transfer switches

Diagnostic messages

Displays diagnostic messages for the engine,

generator, Model RXT transfer switch,

programmable interface module (PIM), and load

control module (LCM) or load shed kit

Over 70 diagnostic messages can be displayed

Maintenance reminders

System settings

System voltage, frequency, and phase

Voltage adjustment

Measurement system, English or metric

ATS status (Model RXT ATS required)

Source availability

ATS position (normal/utility or

emergency/generator)

Source voltage and frequency

ATS control (Model RXT ATS required)

Source voltage and frequency settings

Engine start time delay

Transfer time delays

Voltage calibration

Fixed pickup and dropout settings

Programmable Interface Module (PIM) status

displays

Input status (active/inactive)

Output status (active/inactive)

Load control module (LCM) or load shed kit menus

Load status

Test function

Содержание 10RESV

Страница 1: ...Residential Commercial Generator Sets Models 8 10 12RESV 8 10 12RESVL Controllers RDC2 DC2 TP 6880 10 14a Operation...

Страница 2: ...eadily 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...

Страница 3: ...2 3 7 Automatic Operation with Other Transfer Switches 22 2 4 Exercise 22 2 4 1 Setting the Exerciser 22 2 4 2 Unloaded Cycle Exercise with Complete System Diagnostics 22 2 4 3 Unloaded Full Speed Exe...

Страница 4: ...r 56 4 5 3 Exerciser Reset 56 4 6 Event Log 56 4 7 Maintenance Timer 57 4 8 OnCue Plus Password 57 Section 5 Scheduled Maintenance 59 5 1 Scheduled Maintenance 60 5 1 1 Service Schedule 61 5 2 Lubrica...

Страница 5: ...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 batt...

Страница 6: ...pors 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 ex...

Страница 7: ...erate 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 nois...

Страница 8: ...ardous 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 in...

Страница 9: ...this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe pre...

Страница 10: ...sion control system for the KT725 engine 10RESV RESVL and 12RESV RESVL is EM for U S EPA California and Europe Generator Set Application Kohlerr Power Systems KPS ensures that all Kohlerr generator se...

Страница 11: ...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 Regi...

Страница 12: ...TP 6880 10 14 12 Service Assistance Notes...

Страница 13: ...n required but locks securely to prevent unauthorized access To open the roof insert the tool provided with the enclosure and turn counterclockwise 1 4 turn Then just raise the roof The roof stays ope...

Страница 14: ...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 or the K...

Страница 15: ...or for SiteTecht connection or the Kohler USB utility D Integral Ethernet connector for Kohlerr OnCuer Plus D Built in 2 5 amp battery charger D Remote two wire start stop capability for optional conn...

Страница 16: ...relays are provided for management of non essential secondary loads and two relays are available to control two independent air conditioner loads The LCM is controlled by the RDC2 DC2 controller The...

Страница 17: ...embly and fuel selector valve 7 Fuel solenoid valve 8 Fuel inlet 9 Field connection terminal block and 20 amp resettable circuit breaker behind panel 10 Line circuit breaker 11 120 VAC receptacles for...

Страница 18: ...TP 6880 10 14 18 Section 1 Descriptions and Service Views 21 22 20 20 Lifting holes 21 Air intake 22 Exhaust outlet Figure 1 3 Service View...

Страница 19: ...WARNING 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 i...

Страница 20: ...l 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 t...

Страница 21: ...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...

Страница 22: ...h 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...

Страница 23: ...down 2 4 3 Unloaded Full Speed Exercise The unloaded full speed exercise runsthe generator set at full speed for 20 minutes without transferring the load To set an unloaded full speed exercise follow...

Страница 24: ...s used an ATS fault indicates that the connection to the interface board on the transfer switch has been lost Check the connection to the ATS interface board 2 5 4 Resetting the Controller after a Fau...

Страница 25: ...uipment Batt Chg Flt W Battery charger fault Input to PIM from an external battery charger not the built in battery charger Check external battery charger Battery High W Engine starting battery voltag...

Страница 26: ...generator set in Automatic mode when appropriate Oil Pres Low SD The LOP switch indicates low oil pressure for more than 5 seconds Function becomes active 30 seconds after crank disconnect 30 second i...

Страница 27: ...ostat trips for some reason other than high temperature i e a nuisance trip follow these steps to reset the thermostat 1 Disconnect the utility power to the generator by opening turning OFF the corres...

Страница 28: ...TP 6880 10 14 28 Section 2 Generator Set Operation Notes...

Страница 29: ...trol buttons D Generator set status indicating 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 s...

Страница 30: ...ngs This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller Select Up arrow Figure 3 3 RDC2 Controller Pushbutton Operation LED LED Operation RUN...

Страница 31: ...ee Sections 3 7 through 3 21 for menu diagrams tp6804 Genset Status Running Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK Battery 12 3V Engine Runtime 12345 6 h Date 02DEC2011 Time HR MNpm Acti...

Страница 32: ...ustment for a particular application D Troubleshooting generator set problems Havecontroller setupand adjustmentperformed onlyby an authorized Kohler distributor dealer or authorized representative Th...

Страница 33: ...s 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 Note To change from am to pm press the up arrow key t...

Страница 34: ...ayed 6 Press and HOLD the Select button to enable editing 7 Press the Select button The setting flashes to show that it can be changed For example HR flashes to show that the hour can be changed 8 Pre...

Страница 35: ...D YY HOLD Exercise Freq Weekly Bi Weekly System Phase Language Return Next Exercise HR MN PM MM DD YY Exercise Freq Weekly Exercise Mode Loaded HOLD Exercise Mode Unloaded Cycle Unloaded Full Loaded F...

Страница 36: ...exit the edit mode 3 8 Main Menu Press the Select button once to bring up the main menu Overview is displayed See Figure 3 9 Press the down arrow button to step to the next menu Engine Metering Use th...

Страница 37: ...011 Next Maintenance 150 h or Mar2012 SW Version 12 34 Return Note Actual settings may vary Figure 3 10 Overview Menu 3 10 Engine Metering Menu The engine metering menu displays engine status informat...

Страница 38: ...e calibration mode can be entered from the Generator Metering menu Contact a Kohler authorized distributor dealer for service The Reset Calibration menu allows you to set the voltage reading back to t...

Страница 39: ...own in Figure 3 14 are displayed No changes are allowed from this menu Eng Runtime displays the total number of hours that the generator set engine has run The runtime is not resettable The Next Maint...

Страница 40: ...nt in the field If voltage adjustment is required contact a Kohler authorized distributor or dealer for service Refer to the generator set Installation Manual for instructions to adjust the voltage Se...

Страница 41: ...line to line voltage and follow the instructions in Figure 3 16 to calibrate the voltage readings Emerg Volts tp6810 Normal Voltage L1 L2 240 V Normal Voltage L2 L3 240 V Normal Voltage L3 L1 240 V A...

Страница 42: ...hat 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 value to be changed...

Страница 43: ...it and for systems that use the Kohlerr OnCuer Plus Generator Management System RBUS is a proprietary RS 485 communications protocol The Networking Information menu leads to submenus for network and R...

Страница 44: ...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 the Networking Configu...

Страница 45: ...s generated each time the reset password procedure is performed If the password is reset after the OnCue Plus system has been set up the connection will be lost Disconnect the battery power to the con...

Страница 46: ...layed New password is displayed for approximately 10 seconds Networking Configuration HOLD Reset OnCue Password Yes UP arrow for YES Down arrow for NO Networking Information Networking Status IP Addre...

Страница 47: ...s includes the following optional modules D Model RXT transfer switch D Programmable Interface Module PIM D Load Control Module LCM or load shed kit tp6804 Modules Connected 2 Module Timeouts 1234 Net...

Страница 48: ...the PIM and LCM or load shed kit are printed on the circuit boards inside the enclosures tp6804 Module Status Connected Firmware Ver 122 Module ID 12 S N XXXXXXXXX DeviceType Return S N XXXXXXXXX Devi...

Страница 49: ...user interface A personal computer running Kohlerr SiteTecht software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohlerr OnCuer Plu...

Страница 50: ...ad shed kit 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 the LCM operation refer to TT 1574 pro...

Страница 51: ...oller Procedure to View Event History 1 Press Select to enter the main menu 2 Press the down arrow to step down to the eventlog 3 Press Select to display the most recent event 4 Press the down arrow t...

Страница 52: ...TP 6880 10 14 52 Section 3 RDC2 Controller Operation Notes...

Страница 53: ...r set D Model RXT Automatic Transfer Switch ATS D Load Control Module LCM or load shed kit D Programmable Interface Module PIM DC2 controller features include D Two line x 16 character backlit digital...

Страница 54: ...vent log AUTO Press to place the generator set in Automatic standby mode Press to exit the event log Press and hold AUTO and OFF to reset the maintenance timer EXERCISE When the controller is in AUTO...

Страница 55: ...red OnCue status is displayed only if OnCue password has been reset Figure 4 5 Status Displays Generator Running Genset State Standby Battery 12 3V Runtime 12345 6 h Next Exercise 7d 6h 42m Sample dat...

Страница 56: ...he number of the crank cycle is displayed No button presses are acknowledged during the crank cycles 5 The generator runs through the exercise cycle described in Section 2 4 2 The controller monitors...

Страница 57: ...until Maintenance Timer Reset is displayed 2 Release the OFF and AUTO buttons 4 8 OnCue Plus Password To setthe OnCuerPluspassword on the DC2 controller 1 Press the OFF button and verify that the gene...

Страница 58: ...TP 6880 10 14 58 Section 4 DC2 Controller Operation Notes...

Страница 59: ...enough to cause severe burns 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...

Страница 60: ...ing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble See the Safety Precautions and Instructions at the beginning of...

Страница 61: ...Monthly Visible wear or damage X Quarterly Wire abrasions where subject to motion X X Six Months Wire cable insulation condition X 3 Years or 500 hours Engine and Mounting Visible wear or damage X We...

Страница 62: ...gure 5 1 Oil Check typical 5 2 3 Engine Oil Recommendation Use 5W 30 API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils a...

Страница 63: ...aling surface of the oil filter adapter e Apply a light coat of clean oil to the rubber seal of the new oil filter f Lightly thread the new oil filter by hand until you feel Resistance Then tighten th...

Страница 64: ...lows 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 n...

Страница 65: ...lace all bent or damaged air cleaner components Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure 1 2...

Страница 66: ...the sealing surfaces are bent or damaged 7 When servicing the air cleaner check the air cleaner base Make sure it is secured and not bent or damaged Also check the element cover for damage or improper...

Страница 67: ...at 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 a...

Страница 68: ...ger 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 o...

Страница 69: ...rator set until the engine stops 4 Press the OFF button on the generator set controller 5 8 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hol...

Страница 70: ...TP 6880 10 14 70 Section 5 Scheduled Maintenance Notes...

Страница 71: ...tributors and dealers See TP 6701 SiteTecht Software Operation Manual for more information 6 3 Fault Messages The RDC2 DC2 controller displays fault messages to aid in troubleshooting Selected fault m...

Страница 72: ...supply and valves Engine malfunction Contact an authorized Kohler distributor dealer Gererator thermostat tripped For trips other than temperature nuisance trips reset the thermostat See Section 2 6 N...

Страница 73: ...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...

Страница 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...

Страница 75: ......

Страница 76: ...ne 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 authorized installation s...

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