Installation Residential/Light Commercial Generator Sets Models: 24RCL 30RCL 38RCLB Controller: RDC2 TP-6906 4/16b
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. Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator. Product Identification Information Generator Set Identification Numbers Engine Identification Record the product identification numbers from the generator set nameplate(s).
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 4 Section 3 Generator Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Four-Lead (Single-Phase) Generator Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 12-Lead (Three-Phase) Generator Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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. Disconnect the battery before generator set installation or maintenance.
Propane (LPG)—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.
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 the Model 24RCL, 30RCL, and 38RCLB generator sets. Operation manuals are available separately. See Figure 1 for an illustration of the 24RCL generator set. Kohler strongly recommends that only factoryauthorized distributors or dealers install and service the generator. List of Related Materials Figure 2 identifies related literature available for the generator sets covered in this manual.
Service Assistance For professional advice on generator power requirements and conscientious service, please contact your nearest authorized Kohler distributor/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 decals 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.
Section 1 Installation Instructions 1.1 Introduction Review this entire section and the Safety Precautions before starting the installation procedure. The generator set specification sheet also contains data that may be required during the installation process. The generator set and accessories must be installed by an authorized Kohler distributor/dealer or authorized representative. The installation must comply with the National Electrical Code (NEC), state, and local codes.
Tools Required: D Multimeter (for measuring voltage and current) D Frequency meter (may be part of multimeter) D Pressure gauge or manometer (for measuring fuel pressure) D Torque wrench D Wrenches D Screwdrivers D Socket wrenches or nut drivers D Pliers D Safety glasses or goggles D Drill with bits and hole saw 1.2 Lifting Generator Set WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes.
D Lifting should only be conducted by those trained and experienced in lifting and rigging to achieve a safe and effective lift.
1.3 Location and Mounting 1.3.1 Location Factors The manufacturer recommends mounting the generator set on concrete at ground level. For installations suspended above ground level, including roof installations, weight considerations are especially important. The building engineer must determine whether the structure can support the weight of the generator set.
1.3.4 Prepare Site Choose a location that is at least 0.9 m (3 ft.) from any building or structure and near the incoming gas service. Allow a minimum of 2.4 m (8 ft.) clearance beyond the exhaust end of the generator set. Plan the installation so that the exhaust outlets of the generator set are not directed toward the building or any openings where exhaust gas could be drawn into the building. Install carbon monoxide detectors on each level of any building adjacent to the generator set.
1.4 Electrical System DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. 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. WARNING Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.
1.4.1 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Most field-installed accessory kits include installation instructions. Comply with applicable national, state, and local codes when installing a wiring system. For Canadian installations, refer to the Canadian Electrical Code (CEC). Row Temp.
1.4.2 Terminal Connector Torque Use the torque values shown in Figure 1-7 or Figure 1-8 for terminal connectors. Refer to UL-486A, UL-486B, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. Comply with applicable national, state, and local codes when installing a wiring system.
1.4.3 Ground and Neutral Connections Ground the generator set. The grounding method must comply with NEC and local codes. Connect the ground to the generator set ground lug, terminal GRD inside the junction box (see Figure 1-10). Connect the grounds for utility and low voltage connections to the ground lugs provided in the customer connection box for those specific connections (see Figure 1-10).
1.4.6 Connect AC and DC Wiring Note: Have a licensed electrician make the following electrical connections. All connections must comply with state and local codes. The generator set is equipped with a field-connection terminal block located in the access area below the junction box. Leads have been factory-installed from the junction box to the terminal block for easy field wiring.
Generator Set Connections Use separate conduit for the power cables and the low voltage communication or engine start leads. Local codes and the length of run as well as the transfer switch wire size requirements will determine the wire size needed for the AC leads. Note: Some codes require the use of a disconnect switch. Check the code requirements for your location and install a disconnect switch, if required. 1.
1.4.7 Automatic Transfer Switch Connection WARNING Follow the installation instructions to connect the transfer switch interface board to the appropriate terminals on the generator set. The RDC2 controller uses a Kohler-proprietary communication protocol to communicate with the transfer switch. When connected to a Kohler Model RXT transfer switch, the RDC2 controller provides the following features: Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death.
1 2 Generator Set GND 12VDC RBUS COM PWR Interface Board on the Model RXT Transfer Switch B A 4 RXT A 3 B PWR COM 4 Note: Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS. 1. Customer connection terminal block. See Figure 1-10 for location. Check the decal on the generator set for terminal block connections. 2. Connect one end of each cable shield to GROUND at the generator set. 3. See Figure 1-13 for cable specifications. 4.
Engine start connection for other transfer switches or a remote start/stop switch Note: Do not use the Kohlerr Model RRT transfer switch with Model RCL generator sets. Other Kohler transfer switches, including Model RDT or Model K (MPACt) transfer switches can be used with the Kohler generator sets covered in this document. These transfer switches contain separate ATS controls that do not communicate with the RDC2 controller.
1.4.8 Communication Cable Specifications PWR and COM Connections RBUS Connections A and B For the RBUS communication connections A and B to the Model RXT transfer switch, optional PIM, and/or optional load shed kit, use 20 AWG shielded, twisted-pair communication cable. Belden #9402 (two-pair) or Belden #8762 (single-pair) or equivalent cable is recommended.
1.4.9 System Connections with Accessory Modules one programmable interface module (PIM), and/or one load control module (load shed kit). See Figure 1-14 through Figure 1-17 for connection options with up to three accessory modules. Accessory modules can include one Model RXT transfer switch, GND See Section 1.4.8 for cable size and length specifications.
GND 2 Generator Set 12VDC RBUS COM COM PWR PWR B B A A 3 1 A 1A 3 1 Load Shed Kit B PWR 4 COM 6 4 A B PWR COM RXT* A A B B PWR PWR COM COM 5 Note: See Section 1.4.8, 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. 2. 3. 4. 5. 6. PIM A B PWR COM Generator set terminal block. See Figure 1-10 for location.
3 1 2 COM Generator Set PWR 9402 CABLE B A 12VDC 3 RBUS COM PWR 9402 CABLE B A tp6809 Note: See Figure 1-13 for cable specifications. 1. Customer connection terminal block. See Figure 1-10 for location. Check the decal on the generator set for terminal block connections. 2. Splice 3. Connect all of the shield leads on this end to GROUND at the generator set.
1.5 Engine Starting 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 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.
1.6 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.
1.6.1 Fuel Lines 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. Use the pipe size indicated in Figure 1-18 for the total length of pipe. Gas lines. Never use fuel piping to ground electrical equipment. The gas supplier is responsible for installation, repair, and alteration to gas piping. Use Schedule 40 black-iron pipe for gas piping.
1.6.2 Gas Regulators Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines. See the generator set specification sheet for fuel supply pressure requirements. Primary gas regulator. The primary regulator reduces the high pressure from a tank or transmission line to the lower pressure required by the secondary regulator on the engine. The fuel supplier provides the primary regulator.
1.6.4 Fuel Conversion Procedures The generator set is easily configurable for use with either NG or LPG. System configuration for NG or LPG requires a mechanical setting on the fuel pressure regulator and an electrical connection on the wiring harness. These adjustments will ensure that the proper fuel and spark timing are supplied to the engine. Note: The fuel pressure regulator is factory preset for NG. When using NG, no mechanical adjustment is required.
1.7 Cooling System WARNING Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. The generator set is equipped with a unit-mounted radiator common cooling system. Add coolant before starting the generator set. The system’s major components include two electric fans, a circulating water pump, a radiator, and a thermostat.
1 1.8 Prestart Installation Check 3 2 Review the entire installation section. 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 Air Cleaner. Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine. See the generator set operation manual for instructions. Air Inlets. Check for clean and unobstructed air inlets. GM90230 Coolant Level.
1.9 Set Exerciser 1.10 Operation Tests 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. Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks. Figure 1-25 shows the controller screens. 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.
1.11 OnCue Plus Generator Management System The OnCuer Plus Generator Management System is included with model 24RCL, 30RCL, and 38RCLB generators. OnCue Plus allows monitoring and control of your generator set from a personal computer, smart phone, or tablet. OnCue Plus can also be configured to send email or text message notifications in the event of a generator set fault. See G18-247, Quick Start Guide and TP--6928, OnCue Plus Operation Manual, for instructions.
Notes 38 Section 1 Installation Instructions TP-6906 4/16
Section 2 Accessories 2.1 Introduction WARNING Obtain the most current list of accessories from the generator set specification sheet or by contacting an authorized Kohler distributor/ dealer. Have accessories installed by your local authorized Kohler distributor/dealer or authorized representative. Follow the installation instructions provided with each kit. Use separate conduit for AC and DC leads to reduce the possibility of electrical interference. Use shielded cable for all analog inputs.
Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater. WARNING Hot engine and exhaust system. Can cause severe injury or death. The generator set engine is equipped with valves that eliminate the need to drain the cooling system before installing the block heater.
2.3 Programmable Interface Module (PIM) 2.3.2 The optional Programmable Interface Module (PIM) provides two programmable inputs and six dry contact outputs, four of which are programmable. The PIM with enclosure is shown in Figure 2-3. See TT-1584 for PIM installation and connection instructions. The PIM is mounted in a NEMA 3R aluminum enclosure, which can be mounted indoors or outdoors. See Section 1.4.
2.4 Load Management Two optional load management devices are available for use with single-phase generator sets and a model RXT or RDT transfer switch. Choose one of these two options: For detailed installation and connection instructions, see TT-1609, provided with the load shed kit, or TP-6807, Operation/Installation Manual for the Model RXT transfer switch with combined interface/load management board. 1 D The optional Load Shed Kit mounts inside a model RDT or RXT transfer switch.
Section 3 Generator Reconnection 3.1 Voltage Reconnection The reconnection procedure explains voltage reconnections only. Do not attempt to change the frequency (e.g. from 60 Hz to 50 Hz) in the field. The following instructions explain the reconnection of 12-lead generator sets. In all cases, follow the National Electrical Code (NEC) guidelines. Reconnect the stator leads of the generator set if a different output phase or voltage is desired. Refer to the following procedure and the connection schematics.
3.2 Four-Lead (Single-Phase) Generator Sets 3.3 12-Lead (Three-Phase) Generator Sets Figure 3-1 shows the factory connection for the singlephase 120/240 V 60 Hz generator set. Four-lead, single-phase models are not reconnectable. Three-phase, 12-lead generator sets are reconnectable to the voltages and phases shown on the generator set specification sheet.
ADV-5875E-P Figure 3-2 12-Lead Generator Reconnection TP-6906 4/16 Section 3 Generator Reconnection 45
3.4 Changing System Settings 8. Press the down arrow to step to the next setting. The RDC2 controller’s keypad and display allow the installer to check and change the generator system settings, if necessary. The system settings for each generator model are set at the factory and should not normally require changes. Check the genset system settings and change them, if necessary, after generator reconnection or controller replacement. 9. To exit, press the down arrow button until Return is displayed.
Status Displays System voltage, frequency, and phase adjustments are in the Genset System menu. Overview ----> 1.2 h Engine ----> Metering ATS ----> Configuration * Generator----> Metering Date ----> and Time Genset ----> Information Network ----> Information Genset ----> Run Time PIM Status ----> Genset System ----> Load Control ----> ATS Status ----> Event Log * ATS configuration appears only if a Model RXT transfer switch is connected.
Changing System Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. Press: Display: Overview 1.2 h ----> Press: 2. Press the down arrow button to navigate to the Genset System menu. See Figure 3-4. Press: Display: Genset System ----> 3. Press the Select button to enter the genset system menu. Press: Display: System Voltage: 240 V 4. Press the down arrow button, if necessary, to step to the setting that you want to change. 5.
3.5 Voltage Calibration 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. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.
Generator ----> Metering Three-phase Single-phase Volts L1--L2: 240 V Calibrate Volts L2--L3: 240 V Calibrate Volts L3--L1: 240 V Volts: 240V Frequency: 60.0 Hz Calibrate To Calibrate Voltage: 1. Press Select when the voltage is displayed. The voltage flashes. Calibrate 2. Press the Up or Down arrow button to change the setting. 3. Press the Select button to save the setting. Frequency: 60.0 Hz 4. Press the down arrow button to move to the next menu.
3.5.2 Calibration Using SiteTech Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. Connect a personal computer (laptop) to the controller using a USB cable and follow this procedure to use Kohlerr SiteTecht software to calibrate the controller. The voltage calibration factors are located in the Genset Calibration group in SiteTecht. Find the parameter labelled Genset Calibration Factor Voltage, L1--L2. See Figure 3-8.
# 1 1.
Section 4 Diagrams and Drawings This section contains dimension drawings, wiring diagrams, and schematics for the enclosed generator set. Figure 4-1 lists the drawing numbers and page numbers. Drawings are arranged in alphanumeric order on the following pages. See the generator set Operation Manual for service views, if necessary.
Notes 54 TP-6906 4/16
TP-6906 3/16 Section 8 Diagrams and Drawings Figure 4-2 Schematic Diagram, 24RCL Generator Set, ADV-8554, Sheet 1 of 2 55
Section 8 Diagrams and Drawings Figure 4-3 Schematic Diagram, 24RCL Generator Set, ADV-8554, Sheet 2 of 2 TP-69063/16 -
TP-6906 3/16 Figure 4-4 Dimension Drawing, 24RCL, ADV-8641, Sheet 1 of 2 Section 8 Diagrams and Drawings 57
Section 8 Diagrams and Drawings Figure 4-5 Dimension Drawing, 24RCL, ADV-8641, Sheet 2 of 2 TP-69063/16
TP-6906 3/16 Figure 4-6 Dimension Drawing, 30RCL/38RCLB, ADV-8663, Sheet 1 of 2 Section 8 Diagrams and Drawings 59
Section 8 Diagrams and Drawings Figure 4-7 Dimension Drawing, 30RCL/38RCLB, ADV-8663, Sheet 2 of 2 TP-69063/16
TP-6906 3/16 Section 8 Diagrams and Drawings Figure 4-8 Schematic Diagram, 30RCL/38RCLA Generator Set, ADV-8799, Sheet 1 of 2 61
Section 8 Diagrams and Drawings Figure 4-9 Schematic Diagram, 30RCL/38RCLA Generator Set, ADV-8799, Sheet 2 of 2 TP-69063/16
TP-6906 3/16 Figure 4-10 Wiring Diagram, 24RCL Generator Set, GM92458, Sheet 1 of 2 Section 8 Diagrams and Drawings 63
Section 8 Diagrams and Drawings Figure 4-11 Wiring Diagram, 24RCL Generator Set, GM92458, Sheet 2 of 2 TP-69063/16
TP-6906 3/16 Section 8 Diagrams and Drawings Figure 4-12 Wiring Diagram, 30RCL/38RCLB Generator Set, GM97040, Sheet 1 of 2 65
Section 8 Diagrams and Drawings Figure 4-13 Wiring Diagram, 30RCL/38RCLB Generator Set, GM97040, Sheet 2 of 2 TP-69063/16
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. 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, k 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.
Notes TP-6906 4/16 69
Notes 70 TP-6906 4/16
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-6906 4/16b E 2014, 2015, 2016 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.
