Instruction/ maintenance manual of the product 24RCL Kohler
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Residential/Light Commercial Generator Sets Model: 24RCL Controller: RDC2 TP-6905 6 /14 Operation.
TP-6905 6/14 2 Engine exhaust from this pr oduct contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.
T able of Contents TP-6905 6/14 T able of Contents 3 Product Identification Information 2 ............................................................. Safety Precautions and In structions 5 ......................................................... Introduction 9 .
T able of Contents, continued TP-6905 6/14 T able of Contents 4 3.12 Genset Run Time Menu 37 ................................................ 3.13 Genset Sys tem Menu 38 .................................................. 3.14 A TS Status Menu 39 .....
TP-6905 6/14 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPOR T ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches , switc hgear , and access ories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
TP-6905 6/14 6 Safety Precautions and Instructions metal surface away from the battery . T o avoid sparks , do not disturb the battery charger connec tions while the battery is charging. Always turn the battery charger off before disconnec ting the battery connec tions.
TP-6905 6/14 7 Safety Precautions and Instructions Propane (LP) —Adequate ventilation is mandatory . Because propane is heavier than air, install propane gas detectors low in a room. Inspec t the detectors per the manufac turer ’s instructi ons. Natural Gas —Adequate ventilation is mandatory .
TP-6905 6/14 8 Safety Precautions and Instructions Welding on the generator set. Can cause severe electri cal equipment damage. Before welding on the generator set perform the f ollowing steps: (1) Remove the battery c ables, negative ( - - ) lead first.
TP-6905 6/14 9 Introduction Introduction This manual provides operation instructions for Model 24RCL and 30RCLH residential/light commercial generator sets equipped with the RDC2 generator set/transfer switch controller . This generator set is approved for use in stationary applications in locations served by a reliable utility power source.
TP-6905 6/14 10 Introduction List of Related L iterature Figure 3 identifies related literature available for the generator sets covered in this manual.
TP-6905 6/14 11 Service Assistance Service Assistance For professional advice on generator set power requirements and conscienti ous service, please contact your nearest authorized Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric.
TP-6905 6/14 12 Service Assistance Notes.
TP-6905 6/14 13 Section 1 Service Views Section 1 Service Views 6 1. Oil check (dipstick) 2. Oil fill location (on valve cover ) 3. See cooling system detail 4. Exhaust outlet 5. Enclosure locking tool (shipping location only) 6. Spark plugs 7. EPR (electronic fuel pressure regulator) 8.
TP-6905 6/14 14 Section 1 Se rvice Views Notes.
TP-6905 6/14 15 Section 2 Generator Set O peration Section 2 Generator Set Operation 2.1 Operating Area Carbon monoxide. Can cause severe n ausea, fainting, or death. The exhaust system must be leakproof and routinely ins pected. W ARNING Carbon monoxide sym ptoms.
TP-6905 6/14 16 Section 2 Generator Set Operation 2.3 Exercising th e Generator Set Operate the generator set without load every week or every other week for 20 minutes. Perform all of the prestart checks before starting the exercise procedure. See Section 2.
TP-6905 6/14 17 Section 2 Generator Set O peration Automatic Stop 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 stops.
TP-6905 6/14 18 Section 2 Generator Set Operation D A TS connection. The controller verifies that the Model RXT A TS interface board is connected. D Battery voltage. Battery voltage is checked before exercise to verify engine starting capability . Battery voltage provides a measurement of battery health.
TP-6905 6/14 19 Section 2 Generator Set O peration 2. Press Select button to save the year and move to the month. 3. Use the arrow and select buttons to set the month and the day . 4. The time is displayed with the hour flashing. Use the up or down arrow key to step to the current hour and am or pm setting.
TP-6905 6/14 20 Section 2 Generator Set Operation Overview - - - - > 1.2 h Engine - - - - > Metering tp6810 Generator - - - - > Metering Genset - - - -> Information Genset - - - -> Run .
TP-6905 6/14 21 Section 2 Generator Set O peration tp6809 Genset - - - -> System Next Exercise HR :MN PM MM/DD/YY Exercise Freq: Weekly/Every Other Week Meas.
TP-6905 6/14 22 Section 2 Generator Set Operation 2.6 Faults Selected fault conditions are shown in Figure 2-5. Fault conditions are classified as warnings or shutdowns. If a fault occurs that is not listed in the table, contact an authorized distributor/dealer for service.
TP-6905 6/14 23 Section 2 Generator Set O peration Fault (RDC2) Fault (OnCue r Plus) Condition Check AC Sens Loss Wa r n i n g (1 sec.) Shutdwn (3 sec.) AC Sensing Lost AC Sensing Lost. In Auto mode, generator output AC sens ing is lost. Detec tion begins 10 seconds after crank disc onnect.
TP-6905 6/14 24 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check CoolT empHigh Wa r n i n g Ect Higher Than Expected 1 Coolant temperature is too high. Check c oolant level. Check radiator and fans for obstruction. Contact an authorized distributor/dealer for serv ice and provide the fault code.
TP-6905 6/14 25 Section 2 Generator Set O peration Fault (RDC2) Fault (OnCue r Plus) Condition Check Frequency High Shutdwn High Frequency Governed frequency exceeds 1 10% of the system’s fr equency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine s tart (10 sec ond inhibit).
TP-6905 6/14 26 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check Over Crank Shutdwn Over Crank Three unsucces sful starting attempts . Check the fuel supply , spark plug, and battery . Check f or loose connec tions. Contact an authorized distributor/dealer for serv ice.
TP-6905 6/14 27 Section 2 Generator Set O peration 2.6.5 Event Log The event log displays up to 1000 controller faults and notices, starting with the mo st recent event.
TP-6905 6/14 28 Section 2 Generator Set Operation 2.7.2 A TS Control Seque nce of Operation See Figure 2-8 for time delay settings. Normal Source Fails: 1. The load control contact opens. 2. The engine start time delay times out. 3. The generator set is signaled to start.
TP-6905 6/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set / T ransfer Switch Controller Model 24RCL and 30RCLH generator sets are equipped with the RDC2 generator set/transfer switch controller .
TP-6905 6/14 30 Section 3 RDC2 Controller Operation 3.2.1 Cont roller Keypad The Run, Of f, and Auto buttons control the generator set as described in Figure 3-2. Use the Select, Up arrow , and Down arrow buttons to navigate through the menus and change settings, if necessary .
TP-6905 6/14 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit liquid crystal diode (LCD) display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-4.
TP-6905 6/14 32 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger . Note: T o disconnect controller power , disconnect the battery and the utility power to the generator set.
TP-6905 6/14 33 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-7. Date and T ime are used for this example. 3. Press the Select button to enter the Date and T ime menu.
TP-6905 6/14 34 Section 3 RDC2 Controller Operation 3.6 Controller Menus The following sections show the RDC2 controller menus and submenus. Use the Select button and the up and down arrow buttons to navigate the menus as shown in the diagrams. Note: Use caution when navigating the controller menus.
TP-6905 6/14 35 Section 3 RDC2 Controller Operation 3.8 Overview Menu Overview - - - - > 1.2 h Active Alert (if any) tp6809 Genset Status Standby V oltage: 240V Freq: 60.
TP-6905 6/14 36 Section 3 RDC2 Controller Operation 3.10 Gen erator Metering M enu The generator metering menu displays the generator voltage and frequency . See Figure 3-10. The voltage calibration mode can be entered from the generator metering menu.
TP-6905 6/14 37 Section 3 RDC2 Controller Operation 3.1 1 Generator Set Info rmation Menu The generator set model number and serial numbers are displayed. No changes are allowed f rom 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.
TP-6905 6/14 38 Section 3 RDC2 Controller Operation 3.13 Gen set System Menu The genset system menu displays the system information shown in Figure 3-13. Generator sets are factory set and should not require changes to the system settings in the field.
TP-6905 6/14 39 Section 3 RDC2 Controller Operation 3.14 A T S Status M enu A TS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model A TS is connected to the engine start connections, Remote A TS is displayed on the A TS Status screen.
TP-6905 6/14 40 Section 3 RDC2 Controller Operation 3.15 A TS Configura tion Menu Note: The A TS Configuration menu appears only if a Model RXT transfer switch is connected. Use the A TS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary .
TP-6905 6/14 41 Section 3 RDC2 Controller Operation 3.16 Date an d Time Menu The date and time will typically be set at controller power-up. T o change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu.
TP-6905 6/14 42 Section 3 RDC2 Controller Operation 3.17 Netwo rking Informatio n 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 r OnCue r Plus Generator Management System.
TP-6905 6/14 43 Section 3 RDC2 Controller Operation 3.17.1 Networking Status Submen u The Networking Status submenu contains settings for OnCue r Plus. See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus.
TP-6905 6/14 44 Section 3 RDC2 Controller Operation 3.17.2 Networking Configu ration Submenu (OnCu e Plus Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue r Plus Generator Management System.
TP-6905 6/14 45 Section 3 RDC2 Controller Operation 3.17.3 RBUS Information Submenu The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol.
TP-6905 6/14 46 Section 3 RDC2 Controller Operation 3.17.4 Remote Devices Submen u Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT A TS D Programmable interface module (PIM) D Load control module (LCM) tp6810 Device Sta tus: Connected RD Firmware V er.
TP-6905 6/14 47 Section 3 RDC2 Controller Operation 3.18 Pro grammab le Interface Module (PIM) Menus 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 .
TP-6905 6/14 48 Section 3 RDC2 Controller Operation 3.19 Load Control Me nus The generator set may be connected to a Load Control Module (LCM) or a Model RXT transfer switch equipped with a Load Shed kit. The Load Control menu displays the status of the load control inputs and outputs, and allows a test of the load control output relays.
TP-6905 6/14 49 Section 4 Scheduled Maintenance Section 4 Scheduled Maintenance 4.1 General Mainten ance Accidental starting. Can cause severe i njury or death. Disconnec t the battery cables before working on the generator s et. Remove the negative ( - - ) lead first when disconnec ting the battery .
TP-6905 6/14 50 Section 4 Scheduled Maintenance The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair , or operate the generator set.
TP-6905 6/14 51 Section 4 Scheduled Maintenance 4.2 Service Schedule System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean T est General Maintenance Fluid leaks X Daily Engine oil level X Daily Coolant level 4.
TP-6905 6/14 52 Section 4 Scheduled Maintenance 4.3 Lubrication System 4.3.1 Oil Specifications Use oil that displays the American Petroleum Institute (API) Starburst certification mark FOR GASOLINE ENGINES on the container . Do not use straight-weight oils recommended for industrial or stationary engines.
TP-6905 6/14 53 Section 4 Scheduled Maintenance 2. Replace the oil filter . a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench. Note: On model 30RCLH only , ensure that the oil cooler adapter nut is tightened to specification [T orque = 40 Nm (29.
TP-6905 6/14 54 Section 4 Scheduled Maintenance 4.4 Air Cleaner At the interval specified in the service schedule (Section 4.2), inspect and clean or replace the air cleaner element. Clean the element more frequently in dirty , dusty conditions. Check the element for accumulated oil or dirt that could cause poor performance.
TP-6905 6/14 55 Section 4 Scheduled Maintenance Carbon monoxide dete ctors. Carbon monoxide can cause severe nausea, fainting, or death. Inst all carbon monoxide detectors on eac h level of the building. Locate the detectors to adequately w arn the building’s occupants of t he presence of c arbon monoxide.
TP-6905 6/14 56 Section 4 Scheduled Maintenance 4.6.2 Cooling System Inspectio n T o prevent generator shut down or damage because of overheating: D Keep the cooling air inlets clean and unobstructed .
TP-6905 6/14 57 Section 4 Scheduled Maintenance 4.7 Ignition System Airborne particles. Can cause severe injur y or blind - ness. Wear protective goggles and c lothing when using pow er tools, hand tools , or comp ressed a ir . W ARNING Accidental starting.
TP-6905 6/14 58 Section 4 Scheduled Maintenance Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark plug Built-up deposits and gap between elec trodes closing. Oil or carbon fouling. Clean and regap the s park plug. Oil-fouled spark plug Wet, black deposits on t he insulator shell, bore, and electrodes.
TP-6905 6/14 59 Section 4 Scheduled Maintenance 4.8 Battery Consult the battery manufacturer ’s instructions regarding battery care and maintenance. Sulfuric acid in batteries. Can cause severe i njury or death. Wear protective goggles and clothing.
TP-6905 6/14 60 Section 4 Scheduled Maintenance 4.9 Storage Proced ure Hazardous voltag e. Will cause severe inju ry or death. Disconnec t all power sourc es before opening the enclosure. DANGER Connecting the battery and the battery c harger . Hazardous voltage can cau se severe injury or death.
TP-6905 6/14 61 Section 5 Troubleshooting Section 5 T roubleshooting 5.1 Introduc tion 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 b reaker .
TP-6905 6/14 62 Section 5 Tr oubleshooting 5.5 Generator Set T roubleshooting Figure 5-1 contains generator set troubleshooting, diagnos tic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corr ective Action The generator set does not crank.
TP-6905 6/14 63 Section 5 Troubleshooting 5.6 Controller T roubles hooting Figure 5-2 contains basic troubleshootin g information for the RDC2 controller . Problem Possible Cause Corr ective Action Controller LCD d i s p l a yi so f f . Low or no battery v oltage.
TP-6905 6/14 64 Section 5 Tr oubleshooting Notes.
TP-6905 6/14 Appendix 65 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj.
TP-6905 6/14 66 Appendix kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kil.
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E 2014 by Kohler Co. All rights reserved. TP -6905 6/14 KOHLER CO . Kohler , Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Sing.
An important point after buying a device Kohler 24RCL (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kohler 24RCL yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kohler 24RCL - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 24RCL you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 24RCL will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 24RCL, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kohler 24RCL.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 24RCL. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 24RCL along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
