Installation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL Controller: RDC2 TP-7091 2/21a
WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 5.7.4 Oil Pressure Sensor Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Section 6 Drawings and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it 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.
Fuel System WARNING 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.
Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set 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 batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.
Introduction This manual provides installation instructions for Residential/Commercial Model 14/20RCA/RCAL and 20RCA/RCAL generator sets. See Figure 1. Refer to the Operation Manual for generator set operation and maintenance instructions. The generator set is approved for use in stationary applications in locations served by a reliable utility power source. Kohler strongly recommends that only factoryauthorized distributors or dealers install and service the generator.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Visit the Kohler Co. website at KOHLERPower.com. Look at the labels and decals on your Kohler product 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.
Section 1 Location and Mounting 1.1 Introduction The generator set must be installed outdoors. The exhaust systems on enclosed units are designed for outdoor installation only. DANGER Note: DO NOT install these generator sets inside a building. Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. WARNING Carbon monoxide. Can cause severe fainting, or death.
through the holes in the base to lift the unit. See Figure 1-2 for lifting hole locations. In order to access the lifting holes: 1.3 Generator Set Inspection Complete a thorough inspection of the generator set. Check for the following: 1. Raise the roof. 2. Lift off the exhaust end panel and the air intake end panel. No tools are required to remove the enclosure panels. 3. Lift off the service side panel. 4. Insert lifting bars through the holes in the base to lift the generator set. 1.
area at least 1.2 m (4 ft.) beyond the exhaust end of the generator set. See the dimension drawing in Section 6. 1.4 Location and Mounting Install the generator set outdoors near the incoming gas service. The generator set location must allow easy access for maintenance and service. The required distance from a structure is dependent on state and local codes. See the dimension drawing in Section 6 for the minimum clearance from structures and non-combustible materials.
1.6 Access the Air Intake Area The battery, fuel system, and some electrical connections are located in the air intake area. Remove the enclosure panel to access the air intake area during installation as described below. No tools are required to remove and replace the service-side, air intake end, or exhaust end panels. 3. To make the electrical connections, you will also need to remove the cover panel over the terminal block as shown in Section 3.1.4. 4.
Section 2 Fuel 2.1 Fuel Requirements 2.1.1 The generator set operates using natural gas or LPG fuel. The generator set is EPA-certified for both natural gas and LPG fuels. Because of variable climates and geographical considerations, contact the local fuel supplier for fuel system planning and installation. Figure 2-1 lists the recommended fuel ratings and other fuel supply information for natural gas and LPG fuels.
2.1.2 connections. See Figure 2-4 for the recommended wrench locations. Fuel Pipe Size Ensure that the fuel pipe size and length meet the specifications in Figure 2-3. Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow. Compare the total pipe length with the chart in Figure 2-3 to find the required pipe size. Contact local LPG provider for LPG installation information.
2.2 Fuel Conversion WARNING The multi-fuel system allows conversion from natural gas to LPG (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or an authorized distributor/dealer can convert the fuel system. After converting the fuel system, change the Fuel Type setting on the controller. See the Operation Manual for instructions to change settings at the controller, or use a personal (laptop) computer and Kohler SiteTech software to change the setting.
2.2.1 Fuel Conversion, Original Fuel System, 14RCA/RCAL 1 For natural gas and LPG fuel, orifice fittings are used in the fuel line. See Figure 2-5. The natural gas orifice fitting is silver in color and stamped NG. The LPG fitting is gold in color and stamped LPG. The fittings are threaded. A straight-blade screwdriver is required to remove and replace the fittings.
Procedure to Convert from NG to LPG, 14RCA/L 1. Press the OFF button on the generator set controller. 2. Disconnect the utility power to the generator. Conversion from LPG to Natural Gas, 14RCA/L To convert from LPG to natural gas, repeat the steps above, removing the LPG fuel orifice and installing the NG fitting. Connect ignition timing leads 65 and N3 together for natural gas. 3. Disconnect the generator set engine starting battery, negative (- ) lead first. 1 2 4.
2.2.2 Fuel Conversion, Original Fuel System, 20RCA/RCAL For LPG fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve. To convert to LPG, install the LPG orifice as described below. See Figure 2-8 for the fuel system component locations. Conversion from LPG to Natural Gas, 20RCA/L To convert from LPG to natural gas, repeat the steps above to remove the LPG fuel orifice.
2.2.3 Fuel Conversion, Revised Fuel System The revised fuel system uses a knob that controls a valve on the regulator to select the fuel type. See Figure 2-9 and Figure 2-10. Fuel Selection, Revised Fuel System 1. Press the OFF button on the generator set controller. 2. Disconnect utility power to the generator set (open the corresponding circuit breaker in the distribution panel). 3. Disconnect the generator set engine starting battery, negative (- ) lead first. 1 4. Turn off the fuel supply. 5.
14. Press the OFF button to shut down the generator set. 1 Img_0900 Figure 2-12 Knob Position, LPG 6. On 14 kW models, find the ignition timing leads 65 and N, located near the regulator. See Figure 2-13. a. For natural gas (NG), connect lead 65 to lead N3. b. For LPG, disconnect lead 65 from lead N3. 7. Connect and turn on the fuel supply (Ensure that the fuel supply matches the fuel setting). 8. Reconnect the generator set engine starting battery leads, negative (- ) lead last. 9.
Section 3 Electrical 3.1 Electrical Connections Have an authorized distributor/dealer or a licensed electrician make the following electrical connections. The electrical installation must comply with the National Electrical Code (NEC) class 1 wire designation and all applicable local codes. Canadian installations must comply with the Canadian Electrical Code (CEC) and applicable local codes. DANGER AC circuit protection. All AC circuits must include circuit breaker or fuse protection.
3.1.2 Various regulations and site configurations including the National Electrical Code (NEC), local codes, and the type of transfer switch used in the application determine the grounding of the neutral at the generator. NEC Section 250 is one example that has a very good explanation of the neutral grounding requirements for generators. Grounding Ground the generator set. The grounding method must comply with NEC and local codes.
3.1.4 Field Connections 1 Customer connection points are located as shown in Figure 3-3. Open the enclosure roof and locate the cover panel over the circuit breaker. Remove the cover panel to access the power and load connections. 3 2 Remove the air intake end panel for access to the engine start and communication connections to the transfer switch. See Section 3.3 for more details about the transfer switch connections. Route AC leads through flexible conduit.
6. For connection of optional accessories, including the programmable interface module (PIM), and/or a load shed kit, see Section 3.3.2. Note: Connect the shield on the outside of the accessory communication cable to the ground lug near the terminal block (item 6 in Figure 3-3). 7. If the OnCue Plus Generator Management System will be used with the generator set, run category 5E network cable from the generator set to the customer’s router or modem. a.
3.2 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. 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 Description Battery Installation Procedure Starting batteries are usually the lead-acid type. Use a 12-volt group 51 battery with a minimum rating of 500 cold cranking amps at 0 F. The generator set uses a negative ground with a 12-volt engine electrical system. See Figure 3-5 for battery connections. Make sure that the battery is correctly connected and the terminals are tight. 1. Ensure that the starting battery is fully charged before placing the battery in service.
3.3 ATS and Accessory Communication Connections The following sections cover communication connections from the generator set to automatic transfer switches and RBUS accessories, including the programmable interface module (PIM) and the load shed kit. For the longer cable runs shown in the last two rows of Figure 3-6, use 12 or 14 AWG cable for PWR and COM, and use the 20 AWG communication cable specified above for the A and B connections only.
1 4 2 A Generator Set RXT* B GND PWR 3 COM 4 COM COM PWR PWR RBUS B B A A 4 12 VDC 3 Note: Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS. * RXT transfer switch with standard or combined interface/ load management board. 1. 2. 3. 4. Generator set terminal block. See Figure 3-3 for location. Check the decal on the generator set for terminal block connections. Connect one end of each cable shield to GROUND at the generator set.
3.3.3 maximum cable lengths with 1, to 4 modules per cable run. System Connections with Accessory Modules See Figure 3-9 through Figure 3-13 for connection options to RBUS accessory modules. Note the cable shield connections shown in Figure 3-9. Note: A model RXT transfer switch with combined interface/ load management board acts as two RBUS modules: one RXT transfer switch and one load management device.
GND 2 Generator Set 3 4 12VDC RBUS COM COM PWR PWR B B A 3 Load Shed Kit A 1 A B PWR COM 4 5 A RXT* Note: See Section 3.3.1, Communication Cable Specifications for maximum cable lengths. * RXT transfer switch with standard or combined interface/load management board. Do not use a load shed kit with a combined interface board. 1. Generator set terminal block. See Figure 3-3 for location. Check the decal on the generator set for terminal block connections. 2.
Generator Set RXT ATS Terminal Block Load Shed Kit Notes: See Figure 3-3 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. See Section 3.3.1, Cable Specifications (3 runs with 1 module each shown). PIM See Figure 3-9 for communication connection detail (A and B, PWR and COM). tp6803 Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 3-12.
Generator Set Terminal Block Notes: RXT ATS PIM See Figure 3-3 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. See Section 3.3.1, Cable Specifications. See Figure 3-9 for communication connection detail (A and B, PWR and COM). Connect the cable shield to ground at the generator set. Load Shed Kit Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 3-12.
Section 4 Prestart 4.1 Prestart Installation Check DANGER Review the previous installation sections. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following Prestart Checklist. Prestart Checklist Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Air Cleaner.
4.2 Set the Exerciser Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks. See the generator set Operation Manual for detailed descriptions of the exercise operation. 4.2.1 Setting the Exerciser When power is applied to the RDC2 controller (when the battery or the utility power for the battery charger is connected), you will be prompted to set the date and time, and then to set the exerciser. Date: Setting will flash.
Section 5 Accessories 5.1 Introduction Figure 5-4 shows the location for the carburetor heater kit on a 20 kW generator set. This section describes some of the accessories that are available for the generator sets. Have accessories installed by an authorized distributor/dealer or a licensed electrician. This document does not contain installation instructions for accessories. Follow the installation instructions provided with each kit.
1 1 2 adv-8954 Detail view: tp6195 1. Carburetor heater (air cleaner removed to show heater) 2. Carburetor heater power cord Figure 5-3 Carburetor Heater for 14 kW Models 2 tt1482b 1. Carburetor heater location under air cleaner. Insert from the back of the generator set. 2.
5.3 Programmable Interface Module (PIM) 1 img1061 The optional programmable interface module (PIM) shown in Figure 5-6 provides two programmable inputs and six dry contact outputs, four of which are programmable. See TT-1584 for PIM installation and connection instructions. Also see Section 3.3 of this manual for connection to the generator set. The default settings for the inputs and outputs are shown in Figure 5-7.
PIM Connection Factory Default Setting Input 1 None Input 2 None Output 1 (Relay 1) Run Output 2 (Relay 2) Common Fault Output 3 (Relay 3) Low Battery Voltage (Programmable) Output 4 (Relay 4) Not in Auto (Programmable) Output 5 (Relay 5) Cooldown (Programmable) Output 6 (Relay 6) Normal Source Failure (Programmable) Figure 5-7 PIM Inputs and Outputs 5.
Connect to the Ethernet cable in the customer connection area of the generator set. See Figure 5-8. Use an RJ45 inline coupler, provided with the OnCue Plus kit, to connect the customer’s Ethernet cable to the cable in the customer connection box. 5.5 Load Management Devices Two optional load management devices are available for use with single-phase generator sets and a model RXT or RDT transfer switch: The optional Load Shed Kit mounts inside a Model RDT or RXT transfer switch.
For detailed installation and connection instructions, see the installation instructions provided with the load shed kit or the Operation/Installation Manual for the Model RXT transfer switch. 1 2 3 5.6 PowerSync Automatic Paralleling Module (APM) The PowerSync Automatic Paralleling Module (APM) allows the use of two Model 14RCA or two 20RCA generator sets in a single-phase paralleling system to supply power to one building or site. See Figure 5-11.
Automatic paralleling requires: 5.7 Cold Weather Package Two single-phase Model 14RCA or two single-phase Model 20RCA generator sets as described previously. APM RDC2.4 paralleling firmware for the blue-board controller on each generator set. Download the latest version of paralleling firmware from TechTools. One Model RXT automatic transfer switch (ATS) The cold weather package is recommended for reliable operation at temperatures below 0 C (32 F).
Note: The heaters require a continuous source of AC power. See Figure 5-14 and Figure 5-15 for the power supply voltage required. 2 1 Note: The breather tube heater and oil heater must be used together. GM103794 3 Verify that AC power is connected to the generator set as described in the generator set Installation Manual. The circuit must be backed up by the generator set to provide power at all times. Refer to TT- 1709 for instructions to install the heaters and connect 120VAC power.
1 4 3 2 5 GM101483 1. Heating element 2. Heating probe 3. Thermostat 4. Label 5. 120 VAC male connector (connect to breather tube heater) Figure 5-17 Oil Heater Note: For Models 14RCA(L): If the generator set is equipped with a carburetor heater, obtain kit GM102228-S to replace the breather tube, air cleaner spacer, and gaskets before installing the breather tube and oil heaters.
5.7.4 Oil Pressure Sensor Boot The oil pressure sensor boot protects the oil pressure sensor and its connection from moisture and frost buildup that can cause false low oil level faults. Install the oil pressure sensor boot in locations where the ambient temperature drops below 0 C (32 F). See Figure 5-20 for illustrations of the installed kit. Follow the instructions provided with the kit to install the boot. 1 14 kW Models 1 20 kW Models 1.
Section 6 Drawings and Diagrams Figure 6-1 lists the drawing numbers and page numbers.
Figure 6-2 Dimension Drawing ADV-9746, Sheet 1 48 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-3 Dimension Drawing, ADV- 9746, Sheet 2 TP-7091 2/21 Section 3 Diagrams and Drawings 49
Figure 6-4 Dimension Drawing, ADV-9746, Sheet 3 50 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-5 Dimension Drawing ADV-9746, Sheet 4 TP-7091 2/21 Section 3 Diagrams and Drawings 51
Figure 6-6 Dimension Drawing ADV-9746, Sheet 5 52 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-7 Schematic Diagram, ADV-9236, Sheet 1 TP-7091 2/21 Section 3 Diagrams and Drawings 53
Figure 6-8 Schematic Diagram, ADV-9236, Sheet 2 54 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-9 Schematic Diagram, ADV-9236, Sheet 3 TP-7091 2/21 Section 3 Diagrams and Drawings 55
Figure 6-10 Schematic Diagram, ADV-9236, Sheet 4 56 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-11 Wiring Diagram GM115458 Sheet 1, Single Phase, 2-Pole Circuit Breaker TP-7091 2/21 Section 3 Diagrams and Drawings 57
Figure 6-12 Wiring Diagram GM115458 Sheet 2, Single Phase, 1-Pole Circuit Breaker 58 Section 3 Diagrams and Drawings TP-7091 2/21
Figure 6-13 Wiring Diagram GM115458 Sheet 3, Three Phase, 3-Pole Circuit Breaker TP-7091 2/21 Section 3 Diagrams and Drawings 59
Notes 60 Section 3 Diagrams and Drawings TP-7091 2/21
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.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
TP-7091 2/21a 2018 Kohler Co. All rights reserved. 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.
