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TP-7102 3/20

Appendix 67

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp

ampere

ABDC

after bottom dead center

AC

alternating current

A/D

analog to digital

ADC

advanced digital control;

analog to digital converter

adj.

adjust, adjustment

ADV

advertising dimensional

drawing

Ah

amp-hour

AHWT

anticipatory high water

temperature

AISI

American Iron and Steel

Institute

ALOP

anticipatory low oil pressure

alt.

alternator

Al

aluminum

ANSI

American National Standards

Institute (formerly American

Standards Association, ASA)

AO

anticipatory only

APDC

Air Pollution Control District

API

American Petroleum Institute

approx.

approximate, approximately

APU

Auxiliary Power Unit

AQMD

Air Quality Management District

AR

as required, as requested

AS

as supplied, as stated, as

suggested

ASE

American Society of Engineers

ASME

American Society of

Mechanical Engineers

assy.

assembly

ASTM

American Society for Testing

Materials

ATDC

after top dead center

ATS

automatic transfer switch

auto.

automatic

aux.

auxiliary

avg.

average

AVR

automatic voltage regulator

AWG

American Wire Gauge

AWM

appliance wiring material

bat.

battery

BBDC

before bottom dead center

BC

battery charger, battery

charging

BCA

battery charging alternator

BCI

Battery Council International

BDC

before dead center

BHP

brake horsepower

blk.

black (paint color), block

(engine)

blk. htr.

block heater

BMEP

brake mean effective pressure

bps

bits per second

br.

brass

BTDC

before top dead center

Btu

British thermal unit

Btu/min.

British thermal units per minute

C

Celsius, centigrade

cal.

calorie

CAN

controller area network

CARB

California Air Resources Board

CAT5

Category 5 (network cable)

CB

circuit breaker

CC

crank cycle

cc

cubic centimeter

CCA

cold cranking amps

ccw.

counterclockwise

CEC

Canadian Electrical Code

cert.

certificate, certification, certified

cfh

cubic feet per hour

cfm

cubic feet per minute

CG

center of gravity

CID

cubic inch displacement

CL

centerline

cm

centimeter

CMOS

complementary metal oxide

substrate (semiconductor)

com

communications (port)

coml

commercial

Coml/Rec Commercial/Recreational

conn.

connection

cont.

continued

CPVC

chlorinated polyvinyl chloride

crit.

critical

CSA

Canadian Standards

Association

CT

current transformer

Cu

copper

cUL

Canadian Underwriter’s

Laboratories

CUL

Canadian Underwriter’s

Laboratories

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 resistance

deg.,

degree

dept.

department

dia.

diameter

DI/EO

dual inlet/end outlet

DIN

Deutsches Institut fur Normung

e. V. (also Deutsche Industrie

Normenausschuss)

DIP

dual inline package

DPDT

double-pole, double-throw

DPST

double-pole, single-throw

DS

disconnect switch

DVR

digital voltage regulator

E

2

PROM, EEPROM

electrically-erasable

programmable read-only

memory

E, emer.

emergency (power source)

ECM

electronic control module,

engine control module

EDI

electronic data interchange

EFR

emergency frequency relay

e.g.

for example (

exempli gratia)

EG

electronic governor

EGSA

Electrical Generating Systems

Association

EIA

Electronic Industries

Association

EI/EO

end inlet/end outlet

EMI

electromagnetic interference

emiss.

emission

eng.

engine

EPA

Environmental Protection

Agency

EPS

emergency power system

ER

emergency relay

ES

engineering special,

engineered special

ESD

electrostatic discharge

est.

estimated

E-Stop

emergency stop

etc.

et cetera (and so forth)

exh.

exhaust

ext.

external

F

Fahrenheit, female

FHM

flat head machine (screw)

fl. oz.

fluid ounce

flex.

flexible

freq.

frequency

FS

full scale

ft.

foot, feet

ft. lb.

foot pounds (torque)

ft./min.

feet per minute

ftp

file transfer protocol

g

gram

ga.

gauge (meters, wire size)

gal.

gallon

gen.

generator

genset

generator set

GFI

ground fault interrupter

GND,

ground

gov.

governor

gph

gallons per hour

gpm

gallons per minute

gr.

grade, gross

GRD

equipment ground

gr. wt.

gross weight

H x W x D height by width by depth

HC

hex cap

HCHT

high cylinder head temperature

HD

heavy duty

HET

high exhaust temp., high

engine temp.

hex

hexagon

Hg

mercury (element)

HH

hex head

HHC

hex head cap

HP

horsepower

hr.

hour

HS

heat shrink

hsg.

housing

HVAC

heating, ventilation, and air

conditioning

HWT

high water temperature

Hz

hertz (cycles per second)

IBC

International Building Code

IC

integrated circuit

ID

inside diameter, identification

IEC

International Electrotechnical

Commission

IEEE

Institute of Electrical and

Electronics Engineers

IMS

improved motor starting

in.

inch

in. H

2

O

inches of water

in. Hg

inches of mercury

in. lb.

inch pounds

Inc.

incorporated

ind.

industrial

int.

internal

int./ext.

internal/external

I/O

input/output

IP

internet protocol

ISO

International Organization for

Standardization

J

joule

JIS

Japanese Industry Standard

k

kilo (1000)

K

kelvin

kA

kiloampere

KB

kilobyte (2

10

bytes)

KBus

Kohler communication protocol

kg

kilogram

Содержание RDC2

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

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 69: ...TP 7102 3 20 69 Notes...

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

Страница 71: ......

Страница 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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