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1. Figure 2 2 Clearing a Fault on the RDC2 Controller TP 6804 12 11 3 Press Select Confirm Clear Fault NO is displayed 4 Press the Down arrow button Confirm Clear Fault YES is displayed 5 Press the Select button to enter YES and clear the fault 6 Press the Select button to return to the overview menu The controller changes to OFF mode 7 Press AUTO to put the generator set into automatic mode DC2 Controller Press the OFF button to clear the fault message on the controller Confirm Clear Fault NO Press Up arrow button Confirm Clear Fault YES Fault Message Section 2 Generator Set Operation 25 Fault Message AC Sens Lost Warning W or Shutdown SD W 1 sec SD 3 sec Condition AC sensing lost In Auto mode generator output AC sensing is lost Starts 10 seconds after crank disconnect Warning after 1 second if no output detected after crank disconnect Shutdown after 3 seconds if voltage was present and then lost Contact an authorized distributor dealer for service Accy PwrOver Warning Accessory Power Overload An over current fault short circuit on the accessory controller power output Contact an authorized distributor dealer for service ATS Com Error ATS communication error Warning is displayed if ATS interface connection is lost See Section 2 5 3 Check communication wiri
2. Reset Calib Yes Figure 3 12 Generator Metering Menu 38 Section 3 RDC2 Controller Operation TP 6804 12 11 3 12 Generator Set Information Menu The generator set model number and serial numbers are displayed No changes are allowed from this menu Model and serial numbers are factory set and should not require changes in the field except in the event that the controller is being replaced A personal computer running Kohler Site Tech software is required to enter the generator set model number and serial numbers on a replacement controller Contact an authorized Kohler distributor dealer for service Genset gt Genset M N Information 20RESA Genset S N HHHHHHH Controller S N HHHHHHHH l lt Return tp6804 Figure 3 13 Generator Set Information Menu TP 6804 12 11 3 13 Genset Run Time Menu The data shown in Figure 3 14 are displayed No changes are allowed from this menu The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required The estimated date for the next scheduled maintenance is also displayed The maintenance reminder intervals are based on the engine manufacturer s recommendation for changing the oil Refer to Section 5 Scheduled Maintenance for maintenance instructions After changing the oil
3. AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner service Yearly or hours shown Spark plugs Yearly or hours shown Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 Years General Condition of Equipment Evidence of vibration leakage deterioration unusual or excessive noise or temperature Weekly Interior of sound enclosure x Quarterly Not necessary for maintenance free batteries X Action Service more frequently under extremely dusty dirty conditions Megger is a registered trademark of Biddle Instruments R D Authorized distributor dealer only Replace as necessary TP 6804 12 11 Section 5 Scheduled Maintenance 59 5 2 Lubrication System See the service schedules in Section 5 1 for oil change and oil filter replacement intervals See the service v
4. Operate the generator set only when all guards and electrical enclosures are in place TP 6804 12 11 Section 5 Scheduled Maintenance A WARNING Bes 2 Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 operation 5 1 Scheduled Maintenance Refer to the following service schedules and the runtime hours displayed on the controller display to schedule routine maintenance Intervals are shown in hours of operation and or time intervals i e weekly monthly quarterly etc Have an authorized distributor dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units subject to extreme weather long operating hours or dusty or dirty conditions more frequently Contact an authorized distributor dealer for parts Section 5 Scheduled Maintenance 57 5 1 1 System Component or Procedure Fuel See Section Service Schedule 14RESA RESAL Models Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose
5. Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact an authorized Kohler distributor dealer No AC output Line circuit breaker in the OFF position Place the circuit breaker in the ON position Line circuit breaker tripping because of overload Reduce the load on the generator set Line circuit breaker tripping because of short circuit Contact an authorized Kohler distributor dealer for service Auxiliary winding circuit breaker tripped Reset the circuit breaker located in controller s service access area Contact an authorized Kohler distributor dealer for service if breaker trips repeatedly Low output or excessive drop in voltage Generator set overloaded Reduce the load Generator set stops suddenly Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer Auxiliary winding circuit breaker tripped Reset the circuit breaker located in controller s service access area Contact an authorized Kohler distributor dealer for service if breaker trips repeatedly Fault shutdown Check the controller display for fault messages See Section 2 5 Correct the fault condition and reset the controller Generat
6. Operation Residential Commercial Generator Sets yp gt STE Models 14 20RESA 14 20RESAL Controllers NATIONALLY REGISTERED KOHLER POWER SYSTEMS spats a California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification 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 Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information oooccconccccnncc nr 2 Safety Precautions and Instructions 0c c cece aha aina aaa aaa 7 Introduction 2s stai na a aaa a eee
7. mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 109 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa Mpg mph MS ms nat gas NBS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards 70 Appendix NC NEC NEMA NFPA psi psig pt PTC PTO PVC qt qty R r
8. months or longer Follow the engine manufacturer s recommendations for storage if available Note Run the generator 5 8 1 1 set monthly whenever possible Lubricating System Operate the generator set until it reaches operating temperature or about 15 minutes Stop the generator set While the engine is still warm drain the engine lubrication oil from the engine crankcase Refill engine crankcase with oil See Section 5 2 3 for oil recommendations Run the generator set for a few minutes to distribute the clean oil Stop the generator set 5 8 2 Fuel System 1 2 Start the generator set With the generator set running shut off the gas supply Run the generator set until the engine stops Press the OFF button on the generator set controller 66 Section 5 Scheduled Maintenance 5 8 3 Cylinder Lubrication 1 2 Remove the spark plugs Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs Crank the engine two or three revolutions to lubricate the cylinders 5 8 4 Exterior Preparation 1 2 Clean the exterior surface of the generator set Seal all openings in the engine with nonabsorbent adhesive tape Mask all areas to be used for electrical contact Spread a light film of oil over unpainted metallic surfaces to prevent rust and
9. 20RESA RESAL Figure 5 2 Engine Oil Capacity b Reinstall the dipstick and the oil fill cap c Reconnect the generator set engine starting battery negative lead last d Reconnect the utility power to the generator set e Press the RUN button on the generator set controller The generator set will start f Run the generator set for a minute to allow the oil pressure to reach operating range g Stop the generator set wait 1 minute and then recheck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 5 Reset the maintenance timer on the controller 5 2 5 Resetting the Maintenance Timer 14 20RESA RDC2 1 In the Overview menu step down to the Next Maintenance screen 2 Press the Select button 3 Press the Up arrow button so that Reset Maint Timer Yes is displayed 4 Press the Select button The next maintenance interval and date will be displayed TP 6804 12 11 14 20RESAL DC2 1 Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed 2 Release the OFF and AUTO buttons 5 2 6 Oil Cooler 20RESA RESAL Inspect and clean the oil cooler at the intervals indicated in the service schedule The oil cooler must be kept free of debris See Figure 5 3 for the oil cooler location The oil cooler is lo
10. Check for loose connections Contact an authorized distributor dealer for service Speed Sensor Fault SD Engine speed sensor has failed or engine stalled Contact an authorized distributor dealer for service Engine cooldown runs before shutting down Figure 2 3 Controller Fault Messages TP 6804 12 11 Section 2 Generator Set Operation 27 Notes 28 Section 2 Generator Set Operation TP 6804 12 11 Section 3 RDC2 Controller Operation 3 1 RDC2 Generator Set Transfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set transfer switch controller Model RESAL generator sets are equipped with the DC2 controller See Section 4 for DC2 controller operation information The RDC2 controls the following power system components e Model 14RESA or 20RESA generator set e Model RXT Automatic Transfer Switch ATS e Load Control Module LCM e Programmable Interface Module PIM The RDC2 controller features include e Two line x 16 character backlit digital display with adjustable contrast e OFF AUTO and RUN generator set master control buttons e Generator set status indicating LEDs OFF AUTO RUN e Up Down and Select buttons for navigation through menus and adjustments e Power system indicator LEDs to show utility and generator source status and to show which source utility or generator is supplying power to the load 3 2 Controls and Indi
11. Press to clear faults and reset the controller Press and hold to access the event log 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 mode press to set the exerciser See Section 4 5 When the controller is OFF press and hold to reset the OnCue password See Section 4 8 Figure 4 3 DC2 Controller Pushbutton Operation LED Indication Description RUN LED is on Generator set is running Remote start and stop commands are ignored OFF LED lights for 2 Generator set and controller are off Remote start stop commands have no seconds then flashes effect The exercise cycle will not run every 2 seconds In Auto mode OFF LED Attention required Identify and correct the fault condition before resetting the flashes quickly to indicate controller a fault shutdown AUTO LED is on Automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands or an ATS Time delays operate as described in Section 2 3 Figure 4 4 DC2 Controller LED Operation 52 Section 4 DC2 Controller Operation TP 6804 12 11 4 2 3 LCD Display The controller is equipped with a two line x 16 character backlit digital display with adjustable contrast When the generator set is running the messages sh
12. The engine is equipped with a replaceable high density paper air cleaner element See Figure 5 8 1 Knobs qty 2 2 Cover 3 Paper element 4 Base Figure 5 8 Air Cleaner Components Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace 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 Section 5 Scheduled Maintenance 63 Paper Element Service Replace the paper element at the intervals indicated in the service schedule See Section 5 1 2 for the service schedule See Figure 5 8 for the air cleaner components 1 Loosen the two cover retaining knobs and remove the cover 2 Remove the paper element 3 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 4 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 fit Replace all damaged air cleaner components Note If any loose dirt or debris fell on the air cleaner base when the element was removed c
13. flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS k K kA KB KBus kg hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Kohler communication protocol kilogram Appendix 69 kg cm kgm kg m kHz kJ km kOhm KQ kPa kph kV kVA kVAR kW man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ
14. unified fine thread was NF universal uniform resource locator web address undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer TP 6804 12 11 TP 6804 12 11 O 2011 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS 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 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
15. IP Address 123 456 789 123 Subnet Mask 123 456 789 123 Gateway 123 456 789 123 DNS 1 123 456 789 123 f DNS 2 123 456 789 123 y Ethernet Status Disconnected y OnCue Server 123 456 789 123 lt Return Figure 3 20 Network Status Submenu 44 Section 3 RDC2 Controller Operation tp6804 TP 6804 12 11 3 18 2 Networking Configuration Submenu OnCue Password The networking Configuration menu includes settings used for communication with the Kohler OnCue Home Generator Management System For most applications DHCP is enabled and the IP settings cannot be changed from the controller keypad If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is required then the IP parameters can be modified For applications that require static IP addresses press and hold the select button to enable editing disable DHCP and then step to the next parameters and enter the information If an error occurs while setting a parameter an error message is displayed and then the controller exits the edit mode Previous settings are preserved Networking gt Networking gt Information Status A NY Password For the initial OnCue setup you will be required to reset the OnCue password on the RDC2 controller and then enter itinto the
16. OnCue software To reset the password follow the instructions in Figure 3 21 Note The password is displayed for only 10 seconds Be sure to write down the password and serial number A new password is generated each time the reset password procedure is performed If the password is reset after the OnCue system has been set up the connection will be lost Enter the new password in OnCue to reconnect Networking Configuration Reset OnCue Password Reset OnCue Password No UP arrow for YES a Down arrow for NO Reset OnCue Password Yes Press Select to enter YES or NO as displayed New C password is displayed for DHOP Enabled approximately 10 seconds x S N 1234567 New PW 12345 y lt Return IN tp6804 Figure 3 21 Network Configuration Submenu TP 6804 12 11 Section 3 RDC2 Controller Operation 45 3 18 3 RBUS Information e Model RXT transfer switch The RBUS Information menu contains settings for e Programmable Interface Module PIM remote modules that communicate with the RDC2 controller using RBUS protocol This includes the e Load Control Module LCM following optional modules Networking gt Networking gt Information Status A M ES Networking gt Configuration RBUS gt Modules Connected Information 3 UTE lt Return Remot
17. 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 to increase the hour until the correct hour and pm is displayed 11 In the time format menu press Select and then press the up or down arrow button to change the format 12 hr or 24 hr Press Select to save the displayed format 12 Press the down arrow button Return is displayed lt Return Display Press NS Y 13 Press Select to return to the Date and Time menu L Date gt O Display and Time 14 Press the Up or Down arrow buttons to step to a different menu 15 Press Auto to signal the controller to exit the menus and return to the generator set status display Press O AUTO Genset State Display Standby Note If no buttons are pressed the controller returns to the status display after 5 minutes Section 3 RDC2 Controller Operation 3 6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks 3 6 1 Setting the Exerciser at Controller Power up When battery power is connected to the controller you will be prompted to setthe date and time and then to set the exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next
18. Section 6 Troubleshooting 67 6 5 Troubleshooting Figure 6 2 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Problem Controller display backlight is off Possible Cause Backlight turns off after about 1 minute with no activity Corrective Action Backlight will turn on when a button is pressed or the generator set starts Controller display is off Low or no battery voltage Check connections Check generator set battery See Figure 6 2 The generator set does not crank Battery weak or dead Recharge or replace the battery Battery connections reversed or poor Check the connections Fault shutdown Check the controller display for fault messages See Section 2 5 Correct the fault condition and reset the controller Generator set in the OFF mode Press the RUN button to start the engine or press AUTO to allow remote starting The generator set cranks but does not start starts hard lacks power or operates erratically Air cleaner clogged Clean and or replace the air cleaner Battery weak or dead Recharge or replace the battery Battery connection poor Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary
19. See Section 3 5 for more detailed instructions to change settings on the RDC2 If the battery is disconnected and reconnected during generator set maintenance or service the time date and exercise settings will need to be re entered 3 6 2 Changing the Exercise Settings This section explains how to change the exercise settings after the initial setup Follow the procedure below and see the flowchart in Figure 3 8 to set the exercise time and date mode and frequency Procedure to Set the Exerciser 1 Press the AUTO button on the controller 2 Press the Select button to go to the main menu See Figure 3 9 3 Press the down arrow button to step to the Genset System menu 4 Press the Select button to enter the Genset system menu See Figure 3 8 5 Use the down arrow button to step to the Next Exercise menu If the exerciser is not set No Exercise Scheduled will be displayed 6 Press and HOLD the Select button to enable editing 34 Section 3 RDC2 Controller Operation 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 Press the Up or Down arrow buttons to change the setting 9 Press the Select button to save the setting and move to the next For example save HR setting and move to MN 10 Repeat steps 5 through 9 to change the next item on the line until the desired settings are displayed 11 Press Select t
20. Yearly or 500 hours Change oil Yearly or 100 hours Replace filter Yearly or 200 hours Cooling Air ducts louvers Yearly Exhaust Line Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity Yearly AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner and precleaner service Yearly or 100 hours Spark plugs Yearly or 300 hours Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 Years General Condition of Equipment Evi
21. and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams and drawings from your local distributor dealer 1 2 Engine The generator set has a four cycle twin cylinder air cooled Kohler engine The engine operates on clean burning natural gas or propane LP vapor Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Dependable maintenance free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB emission certification e Digital spark advance optimizes ignition timing for the selected fuel 1 3 Generator Set Enclosure The generator set is housed in an exclusive engineered composite enclosure that is corrosion proof even in harsh seaside environments and impact resistant even in cold weather The enclosure has a hinged locking roof that allows easy access to the generator set controller when 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 open until you are ready to close it Be sure to close and loc
22. and performing other recommended maintenance go to the Overview menu to reset the maintenance timer See Section 5 2 5 for instructions to reset the maintenance timer Eng Runtime 12345 6 h A IN Eng Starts Genset gt Run Time 123456 1 Next Maintenance 150 h or Mar2012 lt Return Figure 3 14 Generator Set Run Time Menu Section 3 RDC2 Controller Operation 39 3 14 Genset System Menu The genset system menu displays the system information shown in Figure 3 15 Generator sets are factory set and should not require changes to the system settings in the field A Kohler authorized distributor or dealer can adjust these settings if necessary If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason see Section 3 5 for instructions to enable editing and change the system settings Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Voltage Regulator VR Voltage Adj The generator set voltage is factory set and typically does not require adjustment in the field If voltage adjustment is required contact a Kohler authorized distributor or dealer for ser
23. connected to the generator set To set a loaded exercise follow the procedure in Figure 3 8 and select Exercise Type Loaded For a loaded exercise with a transfer switch other than a Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions 2 4 5 Power Failure During Exercise Cycle If the utility power is lost during an unloaded exercise the ATS transfers to the emergency source the exercise is ended and the control remains in the AUTO mode If the utility power is lost during a loaded exercise the exercise is ended The ATS remains in the emergency position and the control goes into the AUTO mode 24 Section 2 Generator Set Operation The generator set continues to run and supply power to the load for the duration of the utility power outage When Utility power is restored the ATS will re transfer to the utility source through normal timing sequences 2 5 Faults The RDC2 DC2 controller displays fault messages for generator set warnings and shutdowns Selected fault messages are shown in Figure 2 3 2 5 1 Warnings The controller displays a fault message but the generator set does not shut down on a warning The controller resets automatically after a warning condition is corrected 2 5 2 Shutdowns Under a fault shutdown condition the generator set shuts down automatically and the controller displays a fault message The OFF LED flash
24. connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exh ext F FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt exhaust external Fahrenheit female flat head machine screw fluid ounce
25. i da a as 64 5 6 Exhaust System Liusi ad band dh deca detalles ofa dea eb edad ee 64 B7 BAME mais dos ASS Sa ia tee tes E A ia bea Mediate 65 Table of Contents TP 6804 12 11 Table of Contents continued 5 8 Storage Procedure viii a Renee ee aa aa ele ai dae 66 5 8 1 Lubricating System c ie era nane e E eee eens 66 58 2 Fuel System iseenese nis n ia a e a a A in 66 5 8 3 Cylinder Lubrication oooocoooococonorr rar 66 5 8 4 Exterior Preparation o oooocccccoccoooccncn enes 66 5 8 5 Battery ca Ad eighth sie 66 Section 6 Troubleshooting ococccooccnnnnn eee eee eens eee eee eee eens 67 6 1 Introduction veto da da 67 6 2 FaultMessages Ki aa im i a ade a 67 6 3 Gircult ProtectION sk ku i A i 67 6 3 1 Controller Internal Circuit Protection lt 67 6 3 2 Line Circuit Breaker 0 ees 67 6 3 3 Auxiliary Winding Circuit Breakers 67 6 4 Controller Service Access 0 cece eee tne 67 6 5 Troubleshooting ai i 543 Saad ada a tibet edd 68 Appendix A Abbreviations 0 06 0 etn tenet eens 69 TP 6804 12 11 Table of Contents Notes TP 6804 12 11 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of pot
26. load and restart the generator set Contact an authorized distributor dealer for service Generator VoltageL1 L2 High Generator voltage high Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Generator VoltageL1 L2 Low Generator voltage low Output voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service Lo Crank Vit Low cranking voltage Battery voltage falls below 8 VDC for more than 6 seconds while the starter is engaged Charge or replace the battery Locked Rotor No engine rotation is sensed during cranking Shuts down 3 seconds after the fault is detected Check the battery Check for loose connections Contact an authorized distributor dealer for service MainPwrOverL Shutdown Main power overload An over current fault on the 70 controller power output short circuit Contact an authorized distributor dealer for service Not in Auto The generator set is not in Automatic standby mode Remote start and stop commands from a transfer switch or remote switch will be ignored Press AUTO to place the generator set in Automatic mode when appropriate Over Crank Three unsuccessful starting attempts Check the fuel supply spark plug and battery
27. on the 20RESA RESAL may be operated on natural gas fuel because it is excluded from the requirements of 40 CFR 1048 as a stationary engine The engine used in the Model 20RESA RESAL generator set is certified for emergency standby use only 12 Introduction The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements Figure 3 provides the engine compliance period in hours associated with the category descriptor which may be found on the certification label Emission Compliance Period EPA Category C Category B Category A 250 hours 500 hours 1000 hours CARB Moderate Intermediate Extended 125 hours 250 hours 500 hours Figure 3 Emission Compliance Period Refer to the certification label for engine displacement The exhaust emission control system for the CH740 engines 14RESA RESAL is EM for U S EPA California and Europe The exhaust emission control system for the CH1000 engine 20RESA RESAL is EM for U S EPA California and Europe TP 6804 12 11 For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look at the labels and stickers on your Kohler p
28. settings See Figure 3 7 for an example using the Date and Time settings Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Procedure to Change Settings 1 Press the Select button to enter the main menu 2 Press the down arrow button until the desired menu is displayed The Genset System menu is used for this example See Figure 3 9 3 Press the Select button to enter the genset system displays See Figure 3 7 4 Press the down arrow button to step through the generator set system settings 5 To change any of the genset system settings press the Select button The selected setting flashes 6 Press the up or down arrow buttons to increase or decrease the setting 7 When the desired setting is shown press Select The value stops flashing If there are additional adjustable settings on the screen the next setting flashes For example in the date menu the day month and year can be adjusted 8 Repeat steps 6 and 7 for each setting on the screen 9 Press the down arrow to step to the next screen 10 To exit press the down arrow button until Return is displayed Press the Select button to exit the menu 11 Press the AUTO or OFF button to exit the main menu Note If no buttons are pushed the c
29. successful communication Section 3 RDC2 Controller Operation 47 3 19 Programmable Interface Module PIM Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module PIM This is a status display menu only Input and output settings cannot be changed from the RDC2 controller s user interface PIM Status A lt Return A personal computer running Kohler SiteTech software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohler OnCue Home Management System can be used to turn outputs on and off See the OnCue Software Operation Manual for instructions Input 1 In Active MIA Input 2 In Active y Output 1 In Active t Output 2 In Active y Output 3 In Active y Output 4 In Active t Output 5 In Active 4 Y Output 6 In Active x 4 lt Return tp6810 Figure 3 24 Programmable Interface Module PIM Status Menu 48 Section 3 RDC2 Controller Operation TP 6804 12 11 3 20 Load Control Module LCM Menus The Load Control menu displays the status of the Load Control Module LCM inputs and outputs and allows a test of the LCM output relays Generator current is displayed as a percent of the maximum gen
30. the controller Procedure to View Event History 1 Press Select to enter the main menu 2 Press the down arrow to step down to the event log 3 Press Select to display the most recent event 4 Press the down arrow to step to the next event 5 Use the up and down arrow buttons to view events 50 Section 3 RDC2 Controller Operation 6 Press the Select button to exit the event log To stop viewing the event history before the last event press the select button to return to the main menu Date MO DA YEAR Event Log gt time HR MN event number W S I engine hours event name Press UP and Down arrow M buttons to scroll through events NA A Date MO DA YEAR time HR MN event number W S I engine hours event name Press Select button at any time to return to the main menu Figure 3 26 Event Log TP 6804 12 11 Section 4 DC2 Controller Operation 4 1 DC2 Generator Set Transfer Switch Controller Model RESAL generator sets are equipped with the DC2 generator set transfer switch controller Model RESA generator sets are equipped with the RDC2 generator set transfer switch controller See Section 3 for RDC2 controller operation information The DC2 controls the following power system components e Model 14RESAL or 20RESAL generator set e Model RXT Automatic Transfer Switch ATS e Load Control Module LCM e Programmable Interface Module PIM DC2 controll
31. ATS is connected to the engine start connections Remote ATS is displayed on the ATS Status screen ATS gt Status y x ATS Position Normal Normal Status Not Acceptable Emerg Status Standby Voltage Frequency 12 3 Hz The ATS Status menu displays Model RXT transfer switch and source information The voltage shown in these menus can be calibrated Follow the safety precautions at the beginning of this manuals Use a voltmeter to measure the line to line voltage and follow the instructions in Figure 3 16 to calibrate the voltage readings Note If there is no Model RXT transfer switch connected to the generator set Remote ATS is displayed and the other screens on this page do not appear Reset Calibration lt Return Figure 3 16 ATS Status Menu with Calibration TP 6804 12 11 gt Reset Calib No A Reset Calib Yes Section 3 RDC2 Controller Operation 41 3 16 ATS Configuration Menu Note The ATS Configuration menu appears only if a Model RXT transfer switch is connected Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays and change the settings if necessary Changing ATS Configuration Settings To enable editing press the select butt
32. Automatic Transfer Switch Installation Manual Model RSB Automatic Transfer Switch TP 6803 TP 6807 TP 6345 TP 6486 Operation Manual Model RSB Automatic Transfer Switch TP 6487 Service Manual 14 20RESA RESAL Generator Set TP 6735 TP 6796 TP 6701 Operation Manual OnCue Software Operation Manual SiteTech Software Installation Instructions Load Control Module LCM Installation Instructions Programmable Interface Module PIM Figure 2 Related Literature TT 1574 TT 1584 Introduction 11 Nameplate The following illustration shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual See the service views in Section 1 8 for the nameplate location KOHLER KOHLER CO KOHLER WI USA ODEL SERIAL SPEC BUILD DATE MM YY HZ RPM FUEL VOLTAGE AMPS PHASE KW KVA PF GEN MODEL BATT INSUL NEMA CLASS _ 40 C AMB KW VARIES WITH BTU CONTENT OF FUEL ATL GM12070 Emission Information The Kohlere Model CH740 engine used on the 14RESA RESAL generator set is certified to operate using natural gas or propane fuel The Kohler Model CH1000 engine used on the 20RESA RESAL generator set is certified to operate using propane fuel The CH1000 engine used
33. OK 12 3V Engine Runtime 12345 6h Y Date 02DEC2011 Time HR MNpm Battery Sample data shown tp6804 Figure 3 5 Autopaging Displays Generator Running TP 6804 12 11 The display contrast is adjustable Navigate to the Genset System menu and step down to the Contrast screen Press the Select button and then use the up and down arrow buttons to adjust the contrast See Section 3 5 Changing Settings and Section 3 14 Genset System Menu The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Active Alert Genset Status Standby Battery 12 3V Engine Runtime 12345 6h Y Date 02DEC2011 Time HR MNpm Y Next Exercise 09 00p 09Dec2011 Y Next Maintenance 150 h or Mar2012 Sample data shown tp6804 Figure 3 6 Autopaging Displays Automatic Mode Section 3 RDC2 Controller Operation 31 3 3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built in battery charger Note To disconnect controller power disconnect the utility power to the generator set and disconnect the battery If controller power is disconnected and reconnected you will be prompted to setthe t
34. OMNONAwWNH Figure 1 2 Service View Model 20RESA shown TP 6804 12 11 a a AIR INTAKE SIDE PANEL REMOVED TO SHOW DETAIL 24 RDC2 or DC2 controller Field connection terminal block behind panel Digital spark advance ignition DSAI leads Fuel block 14 kW models or LP orifice location 20 kW models inside hose fitting Fuel inlet Fuel solenoid valve Gas regulator assembly 120 VAC receptacles for optional carburetor heater not shown Engine starting battery location battery purchasd separately Oil drain hose Nameplate location Oil drain valve Section 1 Descriptions and Service Views 19 Notes 20 Section 1 Descriptions and Service Views TP 6804 12 11 Section 2 Generator Set Operation 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Exhaust System Check for exhaust leaks and blockages Check the muffler cond
35. a aaa aa a e aaa a 11 SEIVICE ASSISTANCE Links iais a dada ees 13 Section 1 Descriptions and Service Views ooocccccocccnnnn nnn aaa 15 Act INtrodUCtiOny 3 52 4 a E 15 t2 Engine ks a aa aaa AS ican ats 15 1 3 Generator Set Enclosure soccer ss seraa pan E e cette eens 15 1 4 Altemnator acer est as 7S A A Aa A 15 145 Transfer SWITCH vecino ni anei ie too a tilo 15 67 ControllerS a dd 15 17 ACCESSOS o Raid 18 1 7 1 Carburetor Heater ooooccccccccocco ees 18 1 7 2 Fuel Regulator Heater 20RESA and RESAL only 18 1 7 3 OnCue Home Generator Management System 18 1 74 Programmable Interface Module PIM 0c eee eee 18 1 7 5 Load Control Module LCM kaka 18 187 SONICO VIEWS yoo scien cine vite the ado ath Pie ao ibi 19 Section 2 Generator Set Operation 0 cece cece aaa 21 2 1 Prestart Checklist Liza ania pinasi wine tod ede oe arate ete 21 2 2 Exercising the Generator Set 0 0 cece eects 21 23 Generator Set Operation c erasure cette teens 21 2 3 1 Local Starting and Stopping cece eects 21 2 3 2 Automatic Starting and Stopping lt LL 21 2 3 3 Remote Starting and Stopping lt lt 21 2 3 4 Engine Start Crank Cycle o ooocccccccccccccccccc 21 2 35 Engine Gooldownit Liss a a eee AS id 21 2 3 6 Automatic Operation with Model RXT Transfer Switch 22 2 3 7 Automatic Operation with Model RDT or RSB Transfer S
36. access mini breaker protects the alternator Integral Ethernet connector for Kohler OnCue 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 o Displays diagnostic messages for the engine generator Model RXT transfer switch programmable interface module PIM and load control module LCM o Over 70 diagnostic messages can be displayed Maintenance reminders System settings o System voltage frequency and phase o Voltage adjustment o Measurement system English or metric ATS status Model RXT ATS required o Source availability o ATS position normal utility or emergency generator o Source voltage and frequency ATS control Model RXT ATS required o Source voltage and frequency settings o Engine start time delay o Transfer time delays o Voltage calibration o Fixed pickup and dropout settings Programmable Interface Module status displays PIM o Input status active inactive o Output status active inactive Load control module LCM menus o Load status o Test function TP 6804 12 11 DC2 Controller Features Four button keypad OFF AUTO RUN and EXERCISE pushbuttons LED indicators for OFF AUTO and RUN modes LCD display o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility Scrolling system status display o Generator set stat
37. ad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory RS 485 proprietary communications relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rotate rotating revolutions per min
38. amage Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid 10 Safety Precautions and Instructions Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6804 12 11 This manual provides operation and maintenance instructions for residential commercial model 14 20RESA and RESAL generator sets equipped with Kohler RDC2 or DC2 generator set transfer switch controllers See Figure 1 The RDC2 and DC2 controllers control the generator set and the optional Model RXT transfer switch This generator set is approved for use in stationary applications in locations served by a reliable u
39. arefully remove it and wipe the base clean Be careful that none of it drops into the intake throat 5 Reinstall the paper element onto the air cleaner base Make sure the element is flat and properly seated 6 Install the air cleaner cover and secure with the two retaining knobs 7 When element replacement is necessary order genuine Kohler parts 64 Section5 Scheduled Maintenance 5 5 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See the service view in Section 1 8 for air intake and exhaust locations To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above them Overheating and severe generator damage may occur 5 6 Exhaust System Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components for cracks leaks and corrosion e Check for corroded or broken metal parts and re
40. attery manufacturer s instructions for battery maintenance All generator set models use a negative ground with a 12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 5 9 for typical battery connections bie 2 6 EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 5 9 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease Section 5 Scheduled Maintenance 65 5 8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three
41. cated under the No 2 cylinder shroud Remove the top mounting screw and loosen the two side screws then lift off the cylinder shroud Clean the outside of the oil cooler fins with a brush or with compressed air 1 Oil cooler Figure 5 3 Oil Cooler Location Section 5 Scheduled Maintenance 61 5 3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable 3 Check the spark plug gap using a wire feeler gauge See Figure 5 4 for the recommended spark plug gap Adjust the gap by carefully bending the ground electrode See Figure 5 5 and Figure 5 6 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29 8Nm 18 22 ft lb Generator Set Model 14 20RESA RESAL Spark Plug Gap 0 76 mm 0 030 in Figure 5 4 Spark Plug Gap Figure 5 6 Adjusting the Spark Plug Gap 62 Section 5 Scheduled Maintenance 5 4 Air Cleaner Service 5 4 1 Air Cleaner 14RESA RESAL Models The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 5 7 Cover knob Air cleaner cover Element cover nut Element cover Foam precleaner Air cleaner element Air cleaner base Figure 5 7 Air Cleaner C
42. cators Figure 3 1 illustrates the RDC2 controller See Figure 3 2 for details of the controller s user interface TP 6804 12 11 GM77569 1 User Interface see Figure 3 2 2 Service access see Section 6 4 Figure 3 1 RDC2 Controls and Indicators GM77569 2 line LCD display Up button Select button Down button RUN button and LED Generator power available LED Building on generator power LED Building on utility power LED Utility power available LED OFF button and LED AUTO button and LED These LEDs operate only if a Model RXT transfer switch is connected Figure 3 2 RDC2 User Interface m COMNDTAWON Section 3 RDC2 Controller Operation 29 3 2 1 The RUN OFF and AUTO buttons control the generator set as described in Figure 3 3 Controller Keypad Use the Select Up arrow and Down arrow buttons to navigate through the menus and change settings if necessary See Section 2 3 for operation instructions 3 2 2 LED Indicators LEDs above the RUN OFF and AUTO buttons indicate the mode of operation as shown in Figure 3 4 Power System LEDs indicate the status of the utility power and the generator set and indicate which source is supplying power to the building based on the position of the RXT transfer switch See Figure 3 2 and Figure 3 4 Note The p
43. cnornonn o 36 3 8 Maii Menus it A a os 36 3 9 Overview Men sica A ee eee ee eee 37 3 10 Engine Metering Menu 00 2 cc tet eens 37 3 11 Generator Metering Menu 00 cece cette teens 38 3 12 Generator Set Information Menu LLS kaka 39 3 13 Genset Run Time Menu nananana anaana annara 39 3 14 Genset System Menu sssusa anaana nananana aaa kaikas 40 3 15 ATS Status Men A ola ae a lint s Arad 41 3 16 ATS Configuration Menu oooooccococcco nor 42 3 17 Date and Time Menu 0 ccc tenn ete teen eens 43 3 18 Networking Information Menus 0000 kaka akanai 43 3 18 1 Networking Status Submenu lt kas 44 3 18 2 Networking Configuration Submenu OnCue Password 45 3 18 3 RBUS Information 0 000 0 n eens 46 3 18 4 Remote Devices Submenu 0000 c cece teens 47 3 19 Programmable Interface Module PIM Status Menu 0 0c eee 48 3 20 Load Control Module LCM Menus kaka 49 3 21 Event LOG p noite td bade Mid ee T 50 Section 4 DC2 Controller Operation 0c cece cece eee e eens 51 4 1 DC2 Generator Set Transfer Switch Controller ooo ooooooo 51 4 2 Controls and Indicators oooocoocoornennonnorr o 51 4 2 1 Controller Keypad 0000 naa TOEO ma ES AE IEE ai 52 4 2 2 LEDIndicatorS oso cid sande a a E A E i 52 4 2 3 LOD DISPIAY iio di di bi e 53 4 3 Controller Power oooooc
44. corrosion 5 8 5 Battery Perform battery storage last 1 Press the OFF button on the generator set controller Disconnect the battery negative lead first Clean the battery Place the battery in a warm dry location Connect the battery to a float equalize battery charger or charge the battery monthly using a trickle charger Follow the battery charger manufacturer s recommendations TP 6804 12 11 6 1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems First check for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes of the problem and recommended corrective actions If the procedures in this manual do not explain how to correct the problem contact an authorized Kohler distributor dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to equipment 6 2 Fault Messages The RDC2 DC2 controller displays fault messages to aid in troubleshooting Selected fault messages and recommended checks are listed in Figure 2 3 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 5 4 6 3 Circuit Protection If the generator set circuit breaker trips repeatedly contact an authorize
45. d Kohler distributor dealer for service Controller Internal Circuit Protection 6 3 1 The controller is equipped with internal circuit protection A fault message Accy PwrOver Warning or MainPwrOverL Shutdown is displayed if this internal protection is activated Press OFF to reset Contact an authorized Kohler distributor dealer for service TP 6804 12 11 Section 6 Troubleshooting 6 3 2 Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load If the circuit breaker trips reduce the load and switch the breaker back to the ON position 6 3 3 Auxiliary Winding Circuit Breaker A resettable circuit breaker protects the alternator The circuit breaker is located in the controller s service access area See Figure 6 1 6 4 Controller Service Access The alternator winding circuit breaker is accessible from the front of the controller Remove the service access door to reach the circuit breaker See Figure 6 1 A USB port is also located in the service access area Some controller settings can be adjusted using a laptop computer with Kohler SiteTech software Use a USB cable with a mini B connector to connect the controller to your PC See TP 6701 SiteTech Software Operation Manual for more information 1 USB port mini B 2 Alternator winding circuit breaker Figure 6 1 Controller Service Access cover removed
46. delay may be programmed on the transfer switch To allow the smart engine cooldown on the RDC2 controller to operate most efficiently set the cooldown time on the transfer switch controller to zero or the minimum time allowed Refer to the instructions provided with the transfer switch for more information 2 3 6 Automatic Operation with Model RXT Transfer Switch The Model RXT transfer switch connects to the RDC2 controller through the ATS interface board on the transfer switch Also see the Model RXT Transfer Switch Operation Installation Manual for more information about transfer switch operation The controller must be in AUTO mode for automatic transfer switch operation Automatic Start The RDC2 controller receives utility source voltage sensing data from the Model RXT transfer switch 1 If the utility source voltage falls below an acceptable level 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 is signaled to transfer the load to the emergency source 22 Section 2 Generator Set Operation Automatic Stop with Engine Cooldown 1 When the utility source 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 runs through the engine cooldown cycle and
47. dence of vibration leakage excessive noise temperature or deterioration x Weekly Interior of sound enclosure x Quarterly Not necessary for maintenance free batteries Service more frequently under extremely dusty dirty conditions Megger is a registered trademark of Biddle Instruments 58 Section 5 Scheduled Maintenance Action Authorized distributor dealer only Replace as necessary TP 6804 12 11 5 1 2 Service Schedule 20RESA RESAL Models System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before each use Change oil Yearly or 150 hours Replace filter Yearly or 150 hours Crankcase breather hose Yearly or 500 hours Oil cooler Yearly or 100 hours Cooling Air ducts louvers Yearly Exhaust System Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation charge rate Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity Yearly
48. e gt Devices See Figure 3 23 Net Cycle Time 123ms Module Timeouts 1234 Module Errors 1234 lt Return Figure 3 22 RBUS Information Submenu 46 Section 3 RDC2 Controller Operation TP 6804 12 11 3 18 4 Remote Devices Submenu The serial numbers for the PIM and LCM are printed on the circuit boards inside the enclosures Check the status of remote devices communicating through RBUS Device types can include e Model RXT ATS e Programmable Interface Module PIM e Load Control Module LCM From Figure 3 22 Remote Devices gt O S N XXXXXXXXX lt lt DeviceType gt gt gt S N XXXXXXXXX lt lt DeviceType gt gt gt lt Return A Y ZN Module Status Connected l Comm Errors 12345 f Comm Timeouts 12345 f Module ID Firmware Ver 122 y Dis Connected MM DD YY 12 12 Return gt Figure 3 23 Remote Devices Submenu TP 6804 12 11 Connected Displays the date and time that the device was connected Disconnected Displays the last date and time of
49. e generator set is not running 2 Press and hold the Exercise button until Press Again to Reset OnCue PW is displayed 3 Release the Exercise button and press it again within 5 seconds Note If the Exercise button is not pressed within 5 seconds the controller exits the password reset mode 4 The genset serial number and new password PW will be displayed for 10 seconds Record the password for entry into the OnCue program Section 4 DC2 Controller Operation 55 Notes 56 Section 4 DC2 Controller Operation TP 6804 12 11 A WARNING D AS gt Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setas follows 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 Reconnectthe negative lead last when reconnecting the battery Follow these precautions to prevent the starting ofthe generator set by the remote start stop switch A WARNING Hazardous voltage Moving parts Can cause severe injury or death
50. e most recent Each event is displayed with the date and time of the event the number of the event a letter to indicate whether the event was a warning W shutdown S or informational notice 1 the engine hours at the time of the event and the event description See Figure 4 7 Any Screen Event number W S l engine hours Event name Press OFF Event number W S I engine hours Event name Press AUTO button at any time to exit the event log Figure 4 7 Event Log Procedure to View Event Log 1 Press the OFF button The controller must be OFF to display the event log 2 Press and hold the OFF button until the first event appears on the display 3 Press OFF to step through the other events 4 To exit the Event Log hold the OFF button or press the AUTO button TP 6804 12 11 4 7 Maintenance Timer The maintenance timer keeps track of the time until the next recommended maintenance according to the maintenance schedule for the 14RESAL or 20RESAL generator set Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Section 5 To reset the maintenance timer 1 Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed 2 Release the OFF and AUTO buttons TP 6804 12 11 4 8 OnCue Password To set the OnCue password on the DC2 controller 1 Press the OFF button and verify that th
51. ection 2 3 Utility Power Available Lights when utility power is available Building on Utility Power Lights when the building load is connected to utility power through the RXT transfer switch Generator Power Available Lights when generator power is available Building on Generator Power Lights when the building load is connected to generator power through the RXT transfer switch These LEDs operate only if a Model RXT transfer switch is connected Figure 3 4 RDC2 Controller LED Operation 30 Section 3 RDC2 Controller Operation TP 6804 12 11 3 2 3 LCD Display The controller is equipped with a two line x 16 character backlit digital display with adjustable contrast When the generator is running the controller automatically scrolls through the displays shown in Figure 3 5 When the system is in AUTO the screens shown in Figure 3 6 are displayed When a fault or warning condition exists the controller will show the corresponding message See Section 2 5 for more information about faults Controller menus display power system information including status information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings See Sections 3 7 through 3 21 for menu diagrams gt gt Active Alert Y Genset Status Running f Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure
52. el or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution 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 formation Asuccessful test depends on the ability of the solution to bubble TP 6804 12 11 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts A DANGER Hazardous voltage Will cause severe injury or death This equipment must be instal
53. en utility power is restored the transfer switch transfers the load back to utility runs the generator set with no load to cool down the engine and then stops the generator set 2 3 3 Remote Starting and Stopping A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set Close the switch to start and run the generator set Open the switch to stop the generator set Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown 2 3 4 Engine Start Crank Cycle The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault See Section 2 5 Cranking 1 2 and 3 are displayed during the crank cycle Pressing the OFF button during the crank cycle stops the cranking 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 is set to 5 minutes The engine stops before the cooldown time delay expires if the temperature drops below the cooled down Section 2 Generator Set Operation 21 temperature level or ifthe temperature rises above the high limit during the cooldown cycle If a transfer switch other than the Model RXT is used an additional engine cooldown time
54. ential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6804 12 11 Accidental Starting A WARNING FAS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator se
55. er features include e Two line x 16 character backlit digital display with adjustable contrast e OFF AUTO RUN and EXERCISE generator set control buttons 4 2 Controls and Indicators Figure 4 1 illustrates the DC2 controller See Figure 4 2 for details of the controller s user interface TP 6804 12 11 1 User Interface 2 Service access see Section 6 4 Figure 4 1 DC2 Controls and Indicators E co co OO E OFF AUTO RUN EXERCISE 2 line LCD display EXERCISE button RUN button and LED OFF button and LED AUTO button and LED Figure 4 2 DC2 User Interface Section 4 DC2 Controller Operation 51 4 2 1 Controller Keypad 4 2 2 LED Indicators The RUN OFF and AUTO buttons control the generator LEDs above the RUN OFF and AUTO buttons indicate set as described in Figure 4 3 the mode of operation as shown in Figure 4 4 Use the EXERCISE button to set the exerciser on the DC2 controller See Section 4 5 for instructions to set the exerciser Note A personal computer laptop with Kohler SiteTech software is required for changing settings on the DC2 controller Button Function Press to start the generator set The engine start time delay is ignored The software version and engine model are displayed briefly when RUN is pressed Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle
56. erator capacity The load control module 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 provided with the LCM kit O gt Load Control A Generator Current Bi Load gt Control 1 J lt Return gt 123 IN Test Outputs Push Select blinking A M Input 1 In Active Input 2 In Active y Output 1 Add Shed f Output 2 Add Shed y Output 3 Add Shed Output 4 Add Shed i Output 5 Add Shed 1 Output 6 Add Shed lt Return tp6810 Figure 3 25 Load Control Module LCM Status Menu TP 6804 12 11 Section 3 RDC2 Controller Operation 49 3 21 Event Log The event log displays up to 1000 controller faults and notices starting with the most recent event Events are numbered 1 1000 with 1 being the most recent Each event is displayed with the date and time of the event the number of the event a code to indicate whether the event was a warning W shutdown S or informational notice 1 the engine hours at the time of the event and the event description The time and date for notices I are not stored in
57. es In some cases the engine cooldown cycle runs before the engine shuts down See Figure 2 3 Shutdown switches such as the low oil pressure switch or high engine temperature switch on the generator set will automatically reset when the problem is corrected However the fault condition at the controller does not clear until the controller is reset The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 5 4 for instructions to reset the controller after a fault shutdown 2 5 3 ATS Communication Errors When a Model RXT transfer switch is 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 TP 6804 12 11 2 54 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Check the fault message displayed on the controller and refer to Figure 2 3 to identify and correct the fault condition before proceeding Contact an authorized distributor dealer for service if necessary RDC2 Controller Press the OFF button to reset the controller or follow the procedure below See Figure 2 2 1 While the fault message is displayed press the Select button to go to the Overview menu 2 Press Select again The active fault message is displayed Overview gt 12h Fault Message
58. he low oil pressure shutdown does not protect against low oil level Check the engine oil level regularly as recommended in Section 5 Check for leaks in the lubrication system Check the oil level and add oil if the level is low EngineSpeed High Engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service EngineSpeed Low Engine speed drops below 85 of the normal running speed for more than 3 seconds Reduce the load Contact an authorized distributor dealer for service Exer Not Sch Exercise not scheduled No exercise is scheduled on the controller See Section 3 6 or 4 5 for instructions to set the exerciser Engine cooldown runs before shutting down 26 Section 2 Generator Set Operation TP 6804 12 11 Fault Warning W or Shutdown SD Condition Check Generator Frequency High SD Governed frequency exceeds 110 of the system s frequency setpoint for more than 10 seconds Function becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service Generator 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 Function becomes active 10 seconds after engine start 10 second inhibit Reduce the
59. he paper element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions 1 Press the OFF button on the generator set controller 2 Disconnect the utility power to the generator set 3 Disconnect the generator set engine starting battery negative lead first 4 Loosen the cover retaining knob and remove the cover 5 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element TP 6804 12 11 7 Replace the element if itis dirty bent or damaged 8 Check the air cleaner base Make sure it is secure and not bent or damaged Also check the element cover for damage and fit Replace all damaged air cleaner components Remove any loose dirt or debris from the air cleaner base Wipe the base carefully so that no dirt drops into the intake throat Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary 9 Reinstall the paper element precleaner element cover element cover nut and the air cleaner cover Secure the cover with the cover retaining knob 10 Reconnect the utility power to the generator set 11 Reconnect the generator set engine starting battery negative lead last 5 4 2 Air Cleaner 20RESA RESAL Models
60. hown in Figure 3 9 The controller will exit the main menu after 5 minutes if no buttons are pressed To exit the main menu immediately press the controller s OFF or AUTO button Status Overview gt Displays 12h DA Press the Up and Down arrow buttons Engine to move between menus Metering Press OFF or AUTO to exit the menus Generator gt Metering Genset gt Information Genset gt Run Time gt ATS Status ATS gt Configuration Date gt and Time Network gt Information Load gt Control Event Log gt PIM Status ATS configuration appears only if a Model RXT transfer switch is connected Figure 3 9 RDC2 Main Menu 36 Section 3 RDC2 Controller Operation TP 6804 12 11 3 9 Overview Menu 3 10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3 11 This menu Ovenas O pic M only No settings can be 1 2h if any changed from this menu Y Engine gt Eng Speed Metering I 13600 RPM Genset Status Standby Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK 12 3V Engine Ru
61. ide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TP 6804 12 11 Fuel System A WARNING e E Y b W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fu
62. iews in Section 1 8 for the oil drain oil check oil fill and oil filter locations 5 2 1 Low Oil Pressure Shutdown The low oil pressure LOP shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction Note The LOP shutdown feature does not protect against damage caused by operating when the oil level is low it is not a low oil level shutdown Check the oil level regularly and add oil as needed 5 2 2 Oil Check The generator set is shipped with oil Before operating the generator set check the engine oil in the crankcase See Figure 5 1 Maintain the oil level at or near not over the full mark on the dipstick Add 5W 30 synthetic oil when the oil level is low Check the oil level before each use For extended operation check the oil level every 8 hours Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil Figure 5 1 Oil Check typical 60 Section 5 Scheduled Maintenance 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 and leaves the engine intake valves and pistons cleaner 5 2 4 Oil Change Procedure Note Dispose of all waste materials engine oil fuel filter etc in an environmentally
63. ime date and exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next Repeat until all settings are saved and the controller returns to the main menu See Section 3 5 for more detailed instructions to change settings on the RDC2 See Section 3 6 for more detailed instructions to set the exerciser or change the exercise settings 3 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The RDC2 controller monitors the battery voltage and provides a constant 14 0 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz utility power provided from the building on a breaker protected circuit for the built in battery charger 3 5 Changing Settings Some settings can be changed from the controller keypad The controller settings and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the settings and or output when e The controller has been replaced e The voltage requires adjustment for a particular application e Troubleshooting generator set problems Have controller setup and adjustment performed only by an authorized Kohler distributor dealer or authorized representative 32 Section 3 RDC2 Controller Operation The following procedure explains how to change
64. ional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C 32 F The carburetor heater prevents condensation and carburetor icing The heater requires a continuous source of 120 VAC power See the generator set Installation manual for more information 1 7 2 Fuel Regulator Heater 20RESA and RESAL only An optional fuel regulator heater for the 20RESA 20RESAL is recommended for improved cold starting in locations where the ambient temperature drops below 18 C 0 F The heater requires a continuous source of 120 VAC power See the generator set Installation manual for more information 1 7 3 OnCue Home Generator Management System The Kohler OnCue Home Generator Management System allows monitoring and control of your RESA or RESAL generator set from a personal computer located in your home or at other remote locations OnCue can also be configured to send email or text message notifications in the event of a generator set fault Note Be sure to obtain the correct version of the OnCue kit for the RDC2 DC2 controller OnCue version 3 0 is required for RESA RESAL generator sets equipped with the RDC2 DC2 controller OnCue versions numbered 1 x are not compatible with the RDC2 DC2 controller 18 Section 1 Descriptions and Service Views 1 7 4 Programmable Interface Module PIM The optional Programmable Interface Module PIM provides t
65. ition e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed Oil Level Check the oil level before starting the generator set and at the intervals given in Section 5 Scheduled Maintenance Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Exercising the Generator Set Operate the generator set without load once each week for 20 minutes See Section 2 4 for information about loaded and unloaded exercise modes For instructions to set the exerciser see e Section 3 6 for the RDC2 controller e Section 4 5 for the DC2 controller TP 6804 12 11 2 3 Generator Set Operation 2 3 1 Start Press the RUN button to immediately start the generator set Local Starting and Stopping Stop Press the OFF button The engine stops Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown 2 3 2 Automatic Starting and Stopping An automatic transfer switch monitors the utility power and signals the generator set to start when utility power is lost The ATS then transfers the load to the generator set Wh
66. k and RBUS communication settings Networking gt Networking gt Information Status A A Networking gt Configuration RBUS gt Information lt Return Figure 3 19 Networking Information Menu TP 6804 12 11 Date and Time Date i 02Dec2011 v Time 12 34pm Time Format 12hr 24hr lt Return To change the date and time press the Select button See Figure 3 7 for instructions Figure 3 18 Date and Time Menu See Figure 3 20 See Figure 3 21 See Figure 3 22 tp6810 Section 3 RDC2 Controller Operation 43 3 18 1 Networking Status Submenu The Networking Status submenu contains settings for OnCue See the OnCue Software Operation Manual for information about the appropriate network settings for OnCue Changes to these settings are not typically required 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 the Networking Configuration menu See Section 3 18 2 Networking gt Networking gt Information Status OnCue Status Connected P A J DHCP Enabled f
67. k the enclosure and keep the tool in a secure location TP 6804 12 11 1 4 Alternator The generator uses Kohler s unique PowerBoost voltage regulation system which provides instant response to load changes PowerBoost ensures reliable motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 5 Transfer Switch The RDC2 and DC2 controllers are designed to interface with and control the Kohler Model RXT Automatic Transfer Switch ATS Do not use the Kohler Model RRT transfer switch with the RDC2 or DC2 controller If the power system uses a different model transfer switch the RDC2 and DC2 controllers will not control the transfer switch An ATS other than the Model RXT must be equipped with a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set 1 6 Controllers RESA models are equipped with the Residential Digital Control RDC2 RESAL models use the Digital Control DC2 See Figure 1 1 The controller provides integrated control for the generator set Kohler Model RXT transfer switch programmable interface module PIM and load control module LCM RDC2 RESA DC2 RESAL Figure 1 1 Controllers Section 1 Descriptions and Service Views 15 The contr
68. led and serviced by qualified electrical personnel A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply A CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical 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 the generator set transfer switch and related equipment and electrical circuits Turn offthe main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions 9 Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set
69. n cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first 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 disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases TP 6804 12 11 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Refer to this section for general battery information and maintenance Also consult the b
70. ng between transfer switch interface board and generator set ATS PhaseRot ATS phase rotation mismatch Transfer switch phase rotation does not match ATS will not transfer Correct the ATS connection Refer to the ATS Installation manual wiring diagrams and labels on the transfer switch Aux Input Auxiliary input An optional customer connected input is closed Digital input from optional PIM Check customer supplied equipment Batt Chg Fit Battery charger fault Input to PIM from an external battery charger not the built in battery charger Check external battery charger Battery Voltage High Engine starting battery voltage rises above 16 VDC for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Battery Voltage Low Engine starting battery voltage falls below 12 5 VDC for more than 90 seconds when the engine is not running Not operative during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Charge or replace the battery Engine Oil Pressure Low The LOP switch indicates low oil pressure for more than 5 seconds Function becomes active 30 seconds after crank disconnect 30 second inhibit Note T
71. ntime 12345 6 h Date 02DEC2011 Time HR MNpm Next Exercise 09 00p 09Dec2011 Next Maintenance 150 h or Mar2012 SW Version 12 34 lt Return A NA IN Oil Pressure Switch Normal Oil Temp 123F Battery lt Return Figure 3 11 Engine Metering Menu tp6804 Figure 3 10 Overview Menu TP 6804 12 11 Section 3 RDC2 Controller Operation 37 3 11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency See Figure 3 12 Generator gt Metering A ZN Frequency 1 3 Hz Voltage Calibration A DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel The voltage 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 the original value after calibration if necessary See Figure 3 12 Reset Calibration Reset Calib No gt M A l lt Return
72. o Unloaded Full Speed 4 5 2 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week Follow the procedure below to set the exerciser Procedure to Set the Exerciser 1 Press AUTO Verify that the AUTO LED is on and Utility power is available 2 Press the exercise button to start an unloaded exercise 3 Ifaloaded exercise is required press the Exercise button again within 5 seconds 4 After 5 seconds the generator begins its crank cycles During the crank cycles the 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 the system during the unloaded exercise as described in System Diagnostics 6 After 20 minutes the engine stops automatically The exercise time is set to the time the exercise button is pressed An unloaded or loaded exercise as selected above will occur at the same time every seven days 54 Section 4 DC2 Controller Operation 4 5 3 Exerciser Reset To reset the exerciser to run at a different day and or time follow the procedure in Section 4 5 2 to enter the new exerciser settings The old settings will be replaced by the new time and day 4 6 Event Log The event log displays up to 10 controller faults and notices starting with the most recent event Events are numbered 1 10 with 1 being th
73. o save after all settings have been selected Settings will stop flashing 12 Ifthe generator setis connected to a Kohler Model RXT transfer switch the exercise can be changed to a loaded exercise Set the Exercise Mode to Unloaded Cycle Unloaded Full or Loaded Full RXT ATS required as shown in Figure 3 8 Unloaded Cycle is recommended See Sections 2 4 2 through 2 4 4 for information about the exercise modes 13 Set the exercise frequency weekly or every two weeks Weekly exercises are recommended 14 Press the down arrow button to step to the Return menu Press the Select button to return to the main menu After a scheduled exercise run the next exercise time and date will be updated automatically based on the Exercise Frequency setting Other transfer switches For a loaded exercise with a transfer switch other than a Kohler Model RXT ATS refer to the transfer switch operation manual for instructions Exerciser Reset To reset the exerciser to run at a different day and or time or to change the exercise mode follow the procedure in Section 3 6 2 to change the exerciser settings TP 6804 12 11 Genset gt System Freq System XXX Hz A System Phase Y System Volt Y Battery V Y Next Exercise Next Exercise HR MN PM MM DD YY HR MN PM MM DD YY ES Exercise Mode Exercise Mode Loaded Unl
74. oaded Cycle Unloaded Full Loaded Full Exercise Freq Exercise Freq Weekly Weekly Bi Weekly Language Contrast 50 d lt Return tp6804 If the exerciser has not been set No Exercise Sch will be displayed Figure 3 8 Procedure to Set the Exerciser on the RDC2 Controller TP 6804 12 11 Section 3 RDC2 Controller Operation 35 3 7 RDC2 Controller Menus Controller menus display power system information including status information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings Diagrams in the following sections show howto navigate through the menus Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable If a setting on the controller display is flashing edit mode has been enabled Press the OFF or AUTO button to 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 the UP and DOWN arrow buttons to step up and down through the menus s
75. oller s 2 line LCD screen displays status messages and system settings that are clear and easy to read even in direct sunlight or low light RDC2 Controller Features Six button keypad o OFF AUTO and RUN pushbuttons o 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 o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility in all lighting conditions Scrolling system status display o Generator set status o Voltage and frequency o Engine temperature o Oil pressure o Battery voltage o Engine runtime hours Date and time displays Smart engine cooldown senses engine temperature Digital isochronous governor to 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 o Unloaded weekly exercise with complete system diagnostics o Unloaded full speed exercise o Loaded full speed exercise Model RXT ATS required 16 Section 1 Descriptions and Service Views Front access mini USB connector for SiteTech connection Front
76. omponents Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace 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 TP 6804 12 11 Precleaner Service Use the following procedure to wash and oil the precleaner as indicated in the service schedule Wash and oil the precleaner more often under extremely dusty or dirty conditions 1 Press the OFF button on the generator set controller 2 Disconnect the utility power to the generator set 3 Disconnect the battery negative lead first 4 Loosen the cover retaining knob and remove the cover Remove the precleaner from the paper element Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 5 Saturate the precleaner with new engine oil Squeeze out all of the excess oil 6 Reinstall the precleaner over the paper element 7 Reinstall the air cleaner cover Secure the cover with the cover retaining knob 8 Reconnect the power to the battery charger 9 Reconnect the generator set engine starting battery negative lead last Paper Element Service Use the following procedure to replace t
77. on The value flashes 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 value to be changed Repeat the adjustment process until all values are correct Press the down arrow until Return is displayed Press the select button to return to the main menu 42 Section 3 RDC2 Controller Operation ATS gt Configuration A Normal Freq 12 3 Hz Normal Voltage 12345 6 V Emerg Freq 12 3 Hz Emerg Voltage 12345 6 V Emerg Engine Start 3 sec Transfer From 3sec Normal i Transfer From Emerg 120 sec i lt Return Figure 3 17 ATS Configuration Menu tp6810 TP 6804 12 11 3 17 Date and Time Menu The date and time will typically be set 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 18 3 18 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or LCM and for systems that use the Kohler OnCue Home Generator Management System RBUS is a proprietary RS 485 communications protocol The Networking Information menu leads to submenus for networ
78. ontroller exits the menus and returns to the generator set status display after 5 minutes TP 6804 12 11 Changing Settings on the RDC2 Controller 1 Press the Select button to enter the main menu Overview gt Display 12h 2 Press the down arrow button until the desired menu is displayed See Figure 3 9 Date and Time are used for this example Date gt Press Display and Time 3 Press the Select button to enter the Date and Time menu Date 05Dec2011 Display 4 To change the date and time settings press the Select button again The year will flash Displ Date isplay Peay 05Dec2011 5 Press the up or down arrow buttons to change the year ZN Date Display Pey 05Dec2012 NE 6 When the correct year is shown press the Select button The year is saved and the next setting month flashes Displav Date Pay 05Dec2012 7 Repeat steps 5 and 6 using the arrow and select buttons to set the month and the date Figure 3 7 Changing Settings TP 6804 12 11 8 When the correct date is shown press the Select button The saved date is shown Display Date pee 03Jan2012 9 Press the down arrow button to step to the next menu Press Time Display 01 49pm 10
79. oooononnoo or 53 4 4 Battery Charging naei a ai ka a ey i ede pede eee ete 53 Gba LEXBIGISS L Adi Stes is ahah dad clay he dete le we le fe lee a oe oda 54 4 5 1 Exercise MOd S Lt kiai k edie deeded led aa ia 54 4 5 2 Setting the Exerciser niet akiai 54 4 5 3 Exerciser Reset union ni BE lo hee eee acer Ader eae 54 4 6 Evento ii saben de ae Ate ee Aa eyes 54 4 7 Maintenance Timer 000 ccc tannau a paahi d aAa a 55 4 8 OnCue Password xcs seated fea eta fear aad aie Hits a ata atte ef dis viata 55 Section 5 Scheduled Maintenance 00 0c cece cece eee eee eee eee eens 57 5 1 Scheduled Maintenance 0 n enn eee 57 5 1 1 Service Schedule 14RESA RESAL Models 45 58 5 1 2 Service Schedule 20RESA RESAL Models 05 59 5 2 Lubrication System vomita a ai a i a k a al 60 5 2 1 Low Oil Pressure Shutdown LLP LL kaikas 60 5 2 2 Oil Check asian are eet hee eee ei ee ee 60 5 2 3 Engine Oil Recommendation LL 60 5 2 4 Oil Change Procedure 0 c cece cece eee nes 60 5 2 5 Resetting the Maintenance Timer 0 0 00 e eee ees 61 5 2 6 Oil Cooler 20RESA RESAL 0 0 ccc ccc ences 61 5 3 Spark PI GS iio A A Aa 62 5 4 Air Cleaner Servite ntse aeeie ia a a ata A 62 5 4 1 Air Cleaner 14RESA RESAL Models 0000 cece eee aes 62 5 4 2 Air Cleaner 20RESA RESAL Models 0 0c cee errn 63 5 54 G00lINg SVSIEMiL Kia
80. or set in the OFF mode Press the RUN button to start the engine or press AUTO to allow remote starting Remote stop command received from a remote switch ATS or OnCue Check the remote switch position Check OnCue Engine malfunction Figure 6 2 General Troubleshooting Chart 68 Section 6 Troubleshooting Contact an authorized Kohler distributor dealer TP 6804 12 11 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx APU AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CAT5 CB CC cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required a
81. ower system LEDs operate only if a Model RXT transfer switch is connected They will not operate if a Model RDT or RSB transfer switch is used Button Function Starts the generator set The engine start time delay is ignored Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press OFF to clear faults and reset the controller AUTO Down arrow Places the generator set in Automatic standby mode Use to navigate through menus and change settings This manual contains instructions to navigate the Select controller menus and adjust settings on the RDC2 controller Up arrow Figure 3 3 RDC2 Controller Pushbutton Operation LED Operation Lights when the generator set has been started locally by pressing the RUN button Remote start and stop commands are ignored Lights for 2 seconds then flashes every 2 seconds when the generator set and controller are off Remote start stop commands have no effect The exercise cycle will not run In Auto mode OFF LED flashes quickly to indicate a fault shutdown Attention required Identify and correct the fault condition before resetting the controller Lights when the generator is in automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands or an ATS Time delays operate as described in S
82. own in Figure 4 5 are displayed When the system is in AUTO the LCD display steps through the status messages shown in Figure 4 6 When a fault or warning condition exists the controller will show the corresponding message See Section 2 5 for more information on fault and warning messages The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Active Alert if any Running ATS Normal Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK Y Battery 12 3V Runtime 12345 6 h Next Exercise 7d 6h 42m OnCue Status Disconnected Sample data shown Model RXT ATS required OnCue status is displayed only if OnCue password has been reset Figure 4 5 Status Displays Generator Running TP 6804 12 11 Active Alert if any Y Genset State Standby Y Battery 12 3V Runtime 12345 6 h Next Exercise 7d 6h 42m Next Maint 123h or 12months OnCue Status Disconnected Sample data shown OnCue status is displayed only if OnCue password has been reset Figure 4 6 Status Displays Generator in Standby 4 3 Controller Power The DC2 controller is powered by the generator set engine starting battery Note To disconnect controller power disconnect the u
83. perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous 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 into a utility electrical system can cause severe injury or death to utility personnel working on power lines Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment d
84. place them as needed e Check that the exhaust outlet is clear TP 6804 12 11 5 7 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin 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 safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases ca
85. roduct or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6804 12 11 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Service Assistance 13 Notes 14 Service Assistance TP 6804 12 11 Section 1 Descriptions and Service Views 1 1 Introduction The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual
86. ry acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 lb of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 7 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first 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 disconnecting 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 circui
87. s are performed during this full speed portion of the cycle 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 alertthe operator before an emergency event e Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically a a ao D o o n E o lt Ww Engine Cooldown Exercise Full Speed Diagnostics Figure 2 1 Unloaded Exercise Cycle System Diagnostics During the unloaded exercise the controller monitors the following data The controller display indicates that the generator set is running unless a fault is detected as described below e ATS connection The controller verifies that the Model RXT ATS interface board is connected e Battery voltage Battery voltage is checked before exercise to verify engine starting capability Battery voltage provides a measurement of battery health If the controller detects low battery voltage the condition is indicated on the display e Communication integrity tests J1939 RBUS Ethernet and USB are monitored for messages indicating that the controller and wiring are reliable e Engine speed Engine speed is measured at reduced speed and full speed An overspeed or underspeed condition will result in a fault condition and shutdown e Generator output frequency and voltage Operating the generator a
88. s requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6804 12 11 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational
89. safe manner Drain the oil while it is still warm 1 Drain the oil a Press the OFF button on the generator set controller b Disconnect the utility power to the generator set c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Clean the area around the dipstick and oil fill cap f Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container g Open the oil drain valve on the engine h Remove the dipstick and oil fill cap Allow time for the engine oil to drain completely i Close the oil drain valve Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip j Replace the dipstick 2 Replace the oil filter a Clean the area around the oil filter Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the gasket sealing surface of the oil filter adapter c Apply alight coat of clean oil to the rubber seal of the new oil filter d Install the new oil filter following the instructions provided with the filter TP 6804 12 11 3 Fill with oil a Fillthe engine to the F mark on the dipstick The engine oil capacity is shown in Figure 5 2 See Section 5 2 3 Engine Oil Recommendation for oil selection Generator Set Model Oil Capacity L qt 1 9 2 0 2 8 3 0 14RESA RESAL
90. t full speed allows the Section 2 Generator Set Operation 23 RDC2 DC2 controller to check the output power for correct voltage frequency and stability When the engine is running at full speed the controller verifies that the voltage and frequency are within acceptable limits A fault message is displayed if the voltage or frequency is out of range e Oil pressure Oil pressure is verified to ensure proper lubrication of critical engine components Pressure is monitored at both reduced and full speeds Ifthe oil pressure is low the Low Oil Pressure message is displayed and the generator set shuts down 2 4 3 Unloaded Full Speed Exercise The unloaded full speed exercise runs the generator set at full speed for 20 minutes without transferring the load To set an unloaded full speed exercise follow the procedure in Figure 3 8 and select Exercise Mode Unloaded Full 2 4 4 Loaded Full Speed Exercise with RXT only A loaded exercise starts the generator set ramps up to full speed and then transfers the electrical load from the utility source to the generator set After 20 minutes the load is transferred back to the utility source The engine runs without load for 5 minutes or until cool and then shuts down automatically Note With a loaded exercise power to the building is lost for up to 10 seconds during load transfer For a loaded exercise controlled by the RDC2 or DC2 controller a Model RXT transfer switch must be
91. t 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 battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes 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 safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Batte
92. then stops 2 3 7 Automatic Operation with Model RDT or RSB Transfer Switches If a Kohler Model RDT or RSB transfer switch is used the engine start contacts from the ATS must be connected to engine startleads 3 and 4 on the generator set The controller must be in AUTO mode to respond to remote start stop signals from an ATS or remote switch Press the AUTO button to put the controller into automatic mode Automatic Start The engine start contacts on the ATS close to signal the generator set to start and remain closed while the generator set is running Automatic Stop The engine start contacts on the ATS open to signal the generator set to stop TP 6804 12 11 2 4 Exercise The RDC2 and DC2 controllers can be set to automatically run the generator set atthe same time and day each week Exercising the generator set weekly or every two weeks is required to keep the engine and alternator in good operating condition Three exercise modes are available unloaded cycle unloaded full speed and loaded full speed See Sections 2 4 2 through 2 4 4 for information about the exercise modes A loaded exercise can be set at the RDC2 controller only if a Model RXT transfer switch is connected Note With the RDT and RSB transfer switches it is possible to have two exercise settings one unloaded exercise set at the generator set controller and another exercise set at the ATS controller If the exercise times overlap the ATS e
93. tility power source Have the generator set installed by an authorized distributor dealer or service technician Refer to TP 6803 Installation Manual for installation instructions Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully 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 this manual Keep 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 prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition RESA RESAL Generator Set Figure 1 TP 6804 12 11 Introduction List of Related Literature Figure 2 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 Installation Manual Model 14 20RESA RESAL Generator Set Operation Installation Manual Model RXT Automatic Transfer Switch Operation Installation Manual Model RDT
94. tility power to the generator set and disconnect the battery negative lead first 4 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The DC2 controller monitors the battery voltage and provides a constant 14 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz utility power provided from the building on a breaker protected circuit for the built in battery charger See the Installation Manual for instructions to connect power Section 4 DC2 Controller Operation 53 4 5 Exercise The DC2 controller can be set to automatically run the generator set at the same time and day each week Exercising the generator set weekly is required to keep the engine and alternator in good operating condition A laptop computer with Kohler SiteTech software can be used to change the exercise frequency to every two weeks Use a USB cable to connect the controller to the computer and see TP 6701 SiteTech Operation Manual for instructions 4 5 1 Exercise Modes Unloaded Cycle or Loaded Full Speed exercises can be set from the DC2 controller The Unloaded Cycle exercise mode is the default exercise mode A Model RXT transfer switch is required for the Loaded Full Speed exercise mode See Section 2 4 for more information about the exercise modes A laptop computer with Kohler SiteTech software can be used to change the exercise mode t
95. ts can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING 7 Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 8 Safety Precautions and Instructions Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a full
96. us o Voltage and frequency o Engine temperature o Oil pressure o Battery voltage o Engine runtime hours o Maintenance reminders o OnCue status connected disconnected Date and time displays Smart engine cooldown senses engine temperature Digital isochronous governor to maintain steady state speed at all loads Digital voltage regulation 0 5 RMS no load to full load TP 6804 12 11 Automatic start with programmed cranking cycle Exercise modes o Unloaded weekly exercise with complete system diagnostics o Unloaded full speed exercise o Loaded full speed exercise Model RXT ATS required Front access mini USB connector for SiteTech connection Front access mini breaker protects the alternator Integral Ethernet connector for Kohler OnCue 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 o Displays diagnostic messages for the engine generator set model RXT transfer switch and optional programmable interface module PIM and load control module LCM o Over 70 diagnostic messages can be displayed A laptop computer and Kohler SiteTech software can be used to change system settings or upgrade controller firmware Section 1 Descriptions and Service Views 17 1 7 Accessories The following optional accessories are offered for the RESA and RESAL generator sets 1 7 1 Carburetor Heater An opt
97. ute right side Resistance Temperature Detectors RTU RTV SAE scfm SCR s sec Sl SI EO sil SMTP SN SNMP SPDT SPST spec specs sq sq cm sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC
98. vice Refer to the generator set Installation Manual for instructions to adjust the voltage Setting the Exerciser Use the Genset System menus to set the generator set exerciser Refer to Section 2 4 for instructions to set the exerciser and for more information about exercising the generator set After a scheduled exercise run the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting Adjusting the Display Contrast To adjust the display contrast use the down arrow button to step to the Contrast menu Press the Select button and then use the up and down arrow buttons to adjust the contrast Press the Select button to save the contrast setting 40 Section 3 RDC2 Controller Operation Genset gt p gt System Voltage System 240 V A MY ZN System Freq 60 Hz VR Voltage Adj 240 0V System Phase Single System Battery 12V Next Exercise 06 30p 15Dec2011 Exercise Mode Unloaded Variable Exercise Freq Weekly Meas System English Contrast 50 lt Return Figure 3 15 Genset System Menu tp6810 TP 6804 12 11 3 15 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set If no transfer switch is connected or another model
99. witches 22 A EXECS E cif ste aa re eign dn eatin Themed ed aie ate ede ee Pe ee thie 23 2 4 1 Setting the Exerciser 0000 cece cece eee nets 23 2 4 2 Unloaded Cycle Exercise with Complete System Diagnostics 23 2 4 3 Unloaded Full Speed Exercise 0 0 cece cece eee 24 2 44 Loaded Full Speed Exercise with RXT only LL 24 2 4 5 Power Failure During Exercise Cycle 00sec eee eee 24 20 Faults a A SNC a a Sa Maton Ca a eR a 24 2 5 1 WarniNgS cn ii k ein ii e E a tae ee 24 2 5 2 ShutdOwns iia bei dad Madi a dled ed eae o 24 2 5 3 ATS Communication Errors L 24 2 5 4 Resetting the Controller after a Fault Shutdown 25 Section 3 RDC2 Controller Operation 0c cece eee eee eee eee e eens 29 3 1 RDC2 Generator Set Transfer Switch Controllers 29 3 2 Controls and Indicators 0 00 c cece ete etna 29 3 2 1 Controller Keypad cere cete nra akiai 30 3 2 2 LED Indicators Lota ede Sehr eed eid ide 30 3 2 3 LECDIDIS Play sora anita 31 3 3 Controller POWE Li iki kia nd dices a dr bh ids fee ie 32 3 4 Battery Charging 0 ccc kaka akanai 32 3 5 Changing Settings citar alioli 32 3 6 Setting the Exerciser id aia 34 3 6 1 Setting the Exerciser at Controller Powerup LL 34 3 6 2 Changing the Exercise Settings LL 34 TP 6804 12 11 Table of Contents Table of Contents continued 3 7 RDC2 Controller Menus oooocoocooc
100. wo programmable inputs and six programmable dry contact outputs for connection to customer supplied equipment The outputs are controlled by the RDC2 controller and can also be controlled remotely using the OnCue program The PIM is mounted in a NEMA 3R aluminum enclosure which can be mounted indoors or outdoors See the installation instructions provided with the PIM 1 7 5 Load Control Module LCM The optional Load Control Module LCM provides an automatic load management system to comply with Section 702 5 of NEC 2008 The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes The LCM automatically manages up to six residential loads Four power 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 load on the generator set is monitored and loads are added or shed in the order of their priority See specification sheet G6 120 and the LCM installation instructions for more information TP 6804 12 11 1 8 Service Views N AD Hinged inner cover Hinged roof Air intake Lock Locking tool provided with generator set Exhaust outlet Oil check dipstick Oil fill Lifting holes Muffler Air cleaner Oil filter Line circuit breaker USB connector for firmware updates
101. xercise setting takes priority If a Model RDT or RSB transfer switch is used refer to the instructions provided with the transfer switch to seta 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 to set the date and time and then to set the exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next See Section 3 5 for more detailed instructions to change settings on the RDC2 See Section 3 6 for more detailed instructions to set the exerciser or change the exercise settings The DC2 controller does not prompt you to set the exerciser See Section 4 5 for instructions to set the exerciser on the DC2 2 4 2 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded exercise runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the default exercise setting The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 2 1 and described below TP 6804 12 11 e Runs at reduced speed for 10 minutes to warm up and exercise the engine e Ramps up and runs at full speed for 3 minutes Engine diagnostic
102. y charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short 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 or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of any building adjacent to the generator set Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monox

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