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TP-6905 9/21

10 Introduction

List of Related Literature

Figure 3 identifies related literature available for the

generator sets covered in this manual. Only trained and

qualified personnel should install or service the

generator set.

Literature Type

Part

Number

Specification Sheet, 24RCL

G4- 228

Specification Sheet, 30RCL

G4- 229

Specification Sheet, 38RCLB

G4- 262

Specification Sheet, 24RCLA

G4- 303

Specification Sheet, 30RCLA

G4- 304

Specification Sheet, 38RCLC

G4- 305

Installation Manual,
24RCL/30RCL/38RCLB

TP-6906

Installation Manual,
24RCLA/30RCLA/38RCLC

TP-7202

Operation Manual, KG2204/KG2204T
Engine

TP-6901

Service Manual, Generator Set

TP-6907

Service Manual, KG2204/KG2204T Engine
Mechanical

TP-6902

Service Manual, Engine ECM Diagnostics

TP-6903

Parts Catalog, KG2204/KG2204T Engine

TP-6904

Parts Catalog, 24RCL/A, 30RCL/A,
38RCLB/C Generator Set

TP-6908

User Guide OnCue

r

Plus Software

TP-7006

Operation/Installation Manual, RXT ATS

TP-6807

Operation/Installation Manual, RXT ATS *

TP-7193

Operation/Installation Manual, RDT ATS

TP-6345

Operation/Installation Manual, RDT ATS *

TP-7192

Installation Instructions, Programmable
Interface Module (PIM)

TT-1584

Installation Instructions, Load Shed Kit

TT-1609

Installation Instructions, 50 Amp Power
Relay Modules for Load Management

TT-1646

* ATSs built after 6/15/21

Figure 3

Related Literature

Service Assistance

For professional advice on generator set power

requirements and conscientious service, please contact

your nearest authorized Kohler dealer.

D

Visit the Kohler Co. 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.

Содержание 24RCL

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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: ...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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