Operation Residential/Light Commercial Generator Sets Model: 38RCL 48RCL Controller: RDC2 TP-6810 6/12a
California Proposition 65 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.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 3.13 3.14 3.15 3.16 3.17 4 Genset System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date and Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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 circuits can cause bodily injury and/or equipment damage.
Propane (LP)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions. Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion.
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. Engine block heater. Hazardous voltage can cause severe injury or death. The engine block heater can cause electrical shock.
Introduction This manual provides operation instructions for Model 38RCL and 48RCL 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. Have the generator set installed by an authorized Kohler distributor/dealer or service technician. Refer to the Installation Manual for installation instructions.
List of Related Literature Figure 3 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest authorized Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Notes 12 Service Assistance TP-6810 6/12
Section 1 Service Views 2 1 3 4 5 6 17 7 16 15 14 11 12 13 19 10 21 20 8 9 22 28 18 29 30 31 31 32 GM83070 ADV-8494 8 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 26 25 24 Nameplate location Engine fuses Engine ECM and EPR (electronic fuel pressure regulator) Oil check (dipstick) See cooling system detail Exhaust outlet Enclosure locking tool (shipping location only) Spark plugs Block heater connection valve Block heater (optional) Fuel inlet (1 in.
Notes 14 Section 1 Service Views TP-6810 6/12
Section 2 Generator Set Operation 2.1 Operating Area 2.2 Prestart Checklist WARNING Carbon monoxide. Can cause severe fainting, or death. nausea, The exhaust system must be leakproof and routinely inspected. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.
2.3 Exercising the Generator Set 2.4.5 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 2.5 for instructions to set the automatic exerciser. The engine cooldown time delay allows the engine to run after the loads have been removed. 2.4 Generator Set Operation 2.4.1 Local Starting and Stopping Start: Press the RUN button to immediately start the generator set.
Automatic Stop 1. When the utility source is restored, Emergency-to-Normal time delay starts. the If a Model RDT or RSB transfer switch is used, refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS, if desired. 2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility. 2.5.1 3. The generator set stops.
D ATS connection. The controller verifies that the Model RXT ATS 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. If the controller detects low battery voltage, low battery or low charging battery is displayed and the exercise does not start. D Coolant level check. The coolant level is checked.
5. Press the Select button to save the hour and move to minutes. 5. Use the down arrow button to step to the next Exercise menu. 6. Use the up or down arrow button to change the minutes. 6. Press the Select button. The setting flashes to show that it can be changed. For example, the hour flashes to show that the hour can be changed. 7. Press Select to save the time and move to the next screen. 8. Next Exercise is displayed. Use the up, down, and select buttons to set the exercise time and date.
Status Displays Overview ----> 1.
Genset System ----> System Voltage: 240 V System Freq: 60 Hz VR Voltage Adj: 240.0V System Phase: Single System Battery: 12 V Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY See Section 2.5.7, Changing the Exercise Setting Exercise Mode: Exercise Mode: Unloaded Cycle None/Unloaded Full Sp/ Unloaded Cycle/Loaded Full SP Exercise Freq: Exercise Freq: Weekly Weekly/Every Other Week Meas.
2.6 Faults the transfer switch has been lost. Check the connection to the ATS interface board. 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. 2.6.4 If a programmable interface module (PIM) is connected to the generator set controller, additional faults can be activated by customer-supplied equipment.
Warning (W) or Shutdown (SD) Condition Fault AC Sens Lost W (1 sec.) SD (3 sec.) AC Sensing Lost. In Auto mode, generator output AC sensing is lost. Starts 10 seconds after crank disconnect. Check Contact an authorized distributor/dealer for service. Warning: after 1 second if no output detected after crank disconnect. Shutdown: after 3 seconds if voltage was present and then lost. Accy PwrOver Warning W Accessory Power Overload.
Warning (W) or Shutdown (SD) Condition Fault Check Exer Not Sch W Exercise Not Scheduled. No exercise has been scheduled on the RDC2 controller. See Section 2.5 for instructions to set the exerciser. 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.
2.6.5 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 (I), the engine hours at the time of the event, and the event description.
2.7.2 ATS Control Sequence of Operation 2.7.3 Time Delays Time delays are factory-set to the values shown in Figure 2-8. An authorized distributor/dealer can adjust time delays using a personal computer and Kohlerr SiteTecht software. See Figure 2-8 for time delay settings. Preferred Source Fails: Time delays described in this section operate only when the controller is connected to a Kohlerr Model RXT transfer switch. 1. The load control contact opens. 2. The engine start time delay times out. 3.
Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ Transfer Switch Controller Model 38 RCL and 48RCL generator sets are equipped with the RDC2 generator set/transfer switch controller.
3.2.1 Controller Keypad The Run, Off, and Auto buttons control the generator set as described in Figure 3-3. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.4 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 3-3. The RDC2 controller also has a set of power system LEDs below the pushbuttons.
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 3-5. When the system is in AUTO, the LCD display scrolls through the status messages shown in Figure 3-6. The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast screen.
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 battery and the utility power to the generator set. If controller power is disconnected and reconnected, you will be prompted to set the time, 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.
Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview ----> Press: Display: 1.2 h Press: 2. Press the down arrow button until the desired menu is displayed. See Figure 3-8. Date and Time are used for this example. Date Press: Display: ----> Date: Display: 05Dec2011 Date: 03Jan2012 9. Press the down arrow button to step to the next menu.
3.6 Controller Menus 3.7 Main Menu 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. Press the Select button once to bring up the main menu. Overview is displayed. See Figure 3-8. Press the down arrow button to step to the next menu, Engine Metering. Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3-8.
3.8 Overview Menu Overview ----> 1.2 h 3.9 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3-10. This menu displays status information only. No settings can be changed from this menu. Active Alert (if any) Engine ----> Metering Eng Speed: 1800 RPM Genset Status Standby Oil Pressure: 40 PSI Voltage: 240V Freq: 60.0Hz Coolant Temp: 73 F Engine: 95F Oil: 40 PSI Oil Temp: 73 F Battery 12.3V Battery: 12.3 V Engine Runtime: 27.
Voltage Calibration 3.10 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-11. DANGER The voltage calibration mode can be entered from the generator metering menu. 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.
3.11 Generator Set Information Menu 3.12 Genset Run Time 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 Kohlerr SiteTecht software is required to enter the generator set model number and serial numbers on a replacement controller.
3.13 Genset System Menu The genset system menu displays the system information shown in Figure 3-14. 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.
3.14 ATS Status Menu The ATS Status menu displays Model RXT transfer switch and source information. ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen. The voltage shown in these menus can be calibrated. Contact an authorized distributor or dealer for service if calibration is required.
3.15 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. ATS ----> Configuration Normal Freq: 60.0 Hz Normal Voltage: 240.0 V Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed.
3.16 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 3-17. Date and Time Date: 02Dec2011 Time: 12:34pm Time Format: 12hr|24hr <---- Return tp6810 To change the date and time, press the Select button See Figure 3-7 for instructions.
3.17 Networking Information Menus System. RBUS is a proprietary RS-485 communication protocol. 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 Kohlerr OnCuer Home Generator Management The Networking Information menu leads to submenus for network and RBUS communication settings. Networking----> Information Networking----> Status NS See Figure 3-19.
3.17.1 Networking Status Submenu The Networking Status submenu contains settings for OnCuer. See the OnCue Software Operation Manual for information about the appropriate network settings for OnCue. Networking----> Information Networking----> Status 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 3.17.
OnCue Password 3.17.2 Networking Configuration Submenu (OnCue Password) The networking Configuration menu includes settings used for communication with the Kohlerr OnCuer Home Generator Management System. For the initial OnCue setup, you will be required to reset the OnCue password on the RDC2 controller, and then enter it into the OnCue software. To reset the password, follow the instructions in Figure 3-20.
3.17.3 RBUS Information Submenu D Model RXT transfer switch The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules: D Programmable Interface Module (PIM) Networking----> Information D Load Control Module (LCM) Networking----> Status Networking----> Configuration RBUS ----> Information Modules Connected: 3 <---- Return Remote ----> Devices RD See Figure 3-22.
3.17.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT ATS D Programmable interface module (PIM) D Load control module (LCM) RD S/N: XXXXXXXXX <<*DeviceType*>> S/N: XXXXXXXXX <<*DeviceType*>> ... <---- Return Device Status: Connected Comm. Errors: 12345 Comm. Timeouts: 12345 ModBus ID: 12 Firmware Ver.: 122 Connected: MM/DD/YY 12:12 Connected: Displays date/time device was connected.
3.18 Programmable 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. Input and output settings cannot be changed from the RDC2 controller’s user interface. PIM Status: PIM 1 ----> <---- Return A personal computer running Kohlerr SiteTecht software is required to change the input and output settings. Contact an authorized distributor or dealer for service.
3.19 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. Load ----> Control Generator Current: Generator current is displayed as a percent of the maximum generator 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.
Section 4 Scheduled Maintenance 4.1 General Maintenance WARNING WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. 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.
4.2 Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set. Initial Startup Sequence Check Daily Check for fluid leaks 3 X Check all bolts and nuts for tightness ] 6 X Operation Every 100 Hr. Every 150 Hr. Every 400 Hr. Every 800 Hr. Every 1000 Hr. Every 2000 Hr.
4.3.3 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. CC or CD classification oils, even when labeled Heavy Duty or For Natural Gas Engines are not acceptable. Multi-viscosity oils are recommended.
d. Install the new oil filter following the instructions provided with the filter. 3. Fill with oil. See Figure 4-1 for oil selection and Figure 4-3 for oil capacity. Model Oil Capacity, L (qt.) 38RCL and 48RCL Figure 4-3 4.7 (5.0) 4.4 Air Cleaner At the interval specified in the service schedule, 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.
4.5 Exhaust System 4.6 Cooling System WARNING Carbon monoxide. Can cause severe fainting, or death. WARNING Hot coolant and steam. Can cause severe injury or death. nausea, Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. The exhaust system must be leakproof and routinely inspected. Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death.
4.6.2 Cooling System Inspection To prevent generator shutdown or damage because of overheating: D Keep the cooling air inlets clean and unobstructed D Inspect the radiator’s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins. D Check the hoses and connections for leaks and replace any cracked, frayed, or spongy hoses. D Check the condition and tension of the radiator water pump belt(s). 4.6.
Note: Do not sandblast, wire brush, scrape, or otherwise service spark plugs in poor condition. Obtain a new plug for best results. 4.7 Ignition System Service the spark plugs at the interval specified in the service schedule using the following procedure. 1. Press the OFF button on the RDC2 controller. 2. Disconnect the power to the battery charger. 3. Disconnect the generator set engine starting battery, negative (--) lead first. 4.
10. Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap. See Figure 4-10. Position the side electrode directly over the center electrode. 4.8 Battery Consult the battery manufacturer’s regarding battery care and maintenance. instructions 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 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.
Notes 56 Section 4 Scheduled Maintenance TP-6810 6/12
Section 5 Troubleshooting 5.1 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.
5.5 Generator Set Troubleshooting Figure 5-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem The generator set does not crank. The generator set cranks but does not start, starts hard, lacks power, or operates erratically. No AC output. Low output or excessive drop in voltage. Possible Cause Battery weak or dead. Battery connections reversed or poor. Blown fuse(s). Corrective Action Recharge or replace the battery.
5.6 Controller Troubleshooting Figure 5-3 contains basic troubleshooting information for the RDC2 controller. Problem Possible Cause Corrective Action Controller LCD display is off. Low or no battery voltage. Check connections. Check generator set battery. See Figure 5-2. Controller display backlight is off. Backlight turns off after about 1 minute with no activity. Backlight will turn on when a button is pressed or the generator set starts.
Notes 60 Section 5 Troubleshooting TP-6810 6/12
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.
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 TP-6810 6/12a E 2012 by Kohler Co. All rights reserved. For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call 1-800-544-2444 or visit KohlerPower.
