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Owners Manual - - A & A Power Generators

1. Exercise Freg Weekly Meas System English Contrast 50 lt Return Note Actual settings may vary Figure 3 15 Genset System Menu tp6810 TP 6880 8 14 3 15 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 The voliage shown in these menus can be calibrated connected or another model ATS is connected to the Follow the safety precautions at the beginning of this engine start connections Remote ATS is displayed on manuals Use a voltmeter to measure the line to line the ATS Status screen voltage and follow the instructions in Figure 3 16 to calibrate the voltage readings switch connected to the generator set FOE Note If there is no Model RXT transfer ATS gt Status cte ATS Position Remote ATS is displayed and the other Normal screens on this page do not appear Single phase E Normal Status Not Acceptable Emerg Status Standby Note Sample data shown Three phase Normal Volts 240 0 V Normal Voltage L1 L2 240V Normal Freq Normal Voltage 60 0 Hz L2 L3 240V Emerg Volts Normal Voltage 240 0 V L3 L1 240V Emerg Freq 60 0 Hz Normal Freq 60 0 Hz Normal Rotation Similar screens appear for the emergency source Reset Reset Calibration Calib No Reset tp6810 Figure 3 16 ATS Statu
2. Operation Residential Commercial Generator Sets A IN oo Models 8 10 12RESV 8 10 12RESVL Controllers RDC2 DC2 29001 KOHLER mum POVVER SYSTEMS KOHLER Zu Power Systems an California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Safety Precautions and Instructions 00 ccc ee eee eee 7 INITOAUCLON ae re TTT 11 Generator Set Application ci ana a a ae aan aaa een 12 Service ASSISIANCG As kei ias ku ii a i EA e a
3. turbo typ UF UHF UIF UNC UNF univ URL VHF WCR w w o wt xfmr remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal uniform resource locator web address undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency wait withstand and closing ratin
4. AUTO RUN e Up Down and Select buttons for navigation through menus and adjustments e Power system indicator LEDs to show utility and generator source status and to show which source utility or generator is supplying power to the load 3 2 Controls and Indicators Figure 3 1 illustrates the RDC2 controller See Figure 3 2 for details of the controller s user interface TP 6880 8 14 GM77569 1 User Interface see Figure 3 2 2 USB port mini B see Section 6 2 Figure 3 1 RDC2 Controls and Indicators GM77569 2 line LCD display Up button Select button Down button RUN button and LED Generator power available LED Building on generator power LED Building on utility power LED Utility power available LED OFF button and LED AUTO button and LED These LEDs operate only if a Model RXT transfer switch is connected Figure 3 2 RDC2 User Interface OMONOOAWD Section 3 RDC2 Controller Operation 31 3 2 1 Controller Keypad TheRUN OFF and AUTO buttons controlthe 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 3 for operation instructions 3 2 2 LED Indicators LEDs above the RUN OFF and AUTO buttons indicate the mode of operation as shown in Figure 3 4 Power System LEDs indicate the status of the utility power and the generator set and in
5. Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if eguipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch A WARNING 7 6 S RR Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts TP 6880 8 14 A DANGER
6. button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch A WARNING Gh 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor TP 6880 8 14 Note Dispose of all waste materials engine oil fuel e Apply alight coat of clean oil to the rubber seal filter etc in an environmentally safe manner of the new oil filter Drain the oil while it is still warm f Lightly thread the new oil filter by hand until you feel Resistance Then tighten the filter an Note The oil change procedure requires the use of additional 3 4 turn with an oil filter wrench rags a drain tube and a funnel Follow the instructions and use caution to prevent oil from 3 Fill with oil spilling on or into the alternator 1 Drain the oil Note When the oil is drained some oil remains in the engine The amount of
7. OFF button until the first event appears on the display 3 Press OFF to step through the other events 4 To exitthe Event Log hold the OFF button or press the AUTO button TP 6880 8 14 4 7 Maintenance Timer The maintenance timer keeps track ofthe time until the next recommended maintenance according to the maintenance schedule for the generator set Reset the maintenance timer after changing the oil and performing the other maintenance tasks recommended in Section 5 To reset the maintenance timer 1 Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is displayed 2 Release the OFF and AUTO buttons TP 6880 8 14 4 8 OnCue Plus Password Tosetthe OnCue Plus password on the DC2 controller 1 Press the OFF button and verify that the generator set is not running 2 Press and hold the Exercise button until Press Again to Reset OnCue PW is displayed 3 Release the Exercise button and press it again within 5 seconds Note Ifthe Exercise button is not pressed within 5 seconds the controller exits the password reset mode 4 The genset serial number and new password PW will be displayed for 10 seconds Record the password for entry into the OnCue Plus program Section 4 DC2 Controller Operation 59 Notes 60 Section 4 DC2 Controller Operation TP 6880 8 14 Section 5 Scheduled Maintenance A WARNING aS Accidental starting Can cause severe injury or death
8. Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel 22 Section 2 Generator Set Operation Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or eguipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment To ensure c
9. Pressing the OFF button during the crank cycle stops the cranking No other buttons are acknowledged during the crank cycle TP 6880 8 14 2 3 5 The engine cooldown time delay allows the engine to run after the loads have been removed Engine Cooldown Theengine cooldown time delay is setto 5 minutes The engine stops before the cooldown time delay expires if the temperature drops below the cooled down temperature level or if the temperature rises above the high limit during the cooldown cycle If a transfer switch other than the Model RXT is used an additional engine cooldown time delay may be programmed on the transfer switch To allow the smart engine cooldown on the RDC2 DC2 controller to operate most efficiently set the cooldown time on the transfer switch controller to zero or the minimum time allowed Refer to the instructions provided with the transfer switch for more information 2 3 6 Automatic Operation with Model RXT Transfer Switch The Model RXT transfer switch connects to the RDC2 DC2 controller through the ATS interface board on the transfer switch Also see the Model RXT Transfer Switch Operation Installation Manual for more information about transfer switch operation The controller must be in AUTO mode for automatic transfer switch operation Automatic Start The RDC2 DC2 controller receives utility source voltage sensing data from the Model RXT transfer switch 1 If the utility source voltage falls be
10. Rotate the air cleaner cover levers outward to unlock cover remove the air cleaner cover 5 Remove the paper element from the base 6 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 7 When servicing the air cleaner check the air cleaner base Make sure it is secured and not bent or damaged Also check the element cover for damage or improper fit Replace all damaged air cleaner components Note If any loose dirt or debris fell on the air cleaner base when the element was removed carefully remove itand wipethe base clean Be carefulthat none of it drops into the intake throat 8 Reinstall the paper element onto the air cleaner base Make sure the element is flat and properly seated 9 Position the air cleaner cover with levers outward over air cleaner turn levers inward to lock 10 When element replacement is necessary order genuine Kohler parts 11 Reconnect the power to the battery charger 12 Reconnect the generator set engine starting battery negative lead last TP 6880 8 14 5 5 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is disch
11. Select to save the displayed format 12 Press the down arrow button Return is displayed Press 13 Press Select to return to the Date and Time menu b Bical Date gt ress isplay play and Time lt Return Display 14 Press the Up or Down arrow buttons to stepto a different menu 15 Press Auto to signal the controller to exit the menus and return to the generator set status display Press O AUTO Genset State Display Standby Note If no buttons are pressed the controller returns to the status display after 5 minutes Section 3 RDC2 Controller Operation 35 3 6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks 3 6 1 Setting the Exerciser at Controller Power up When battery power is connected to the controller you will be prompted to set the date and time and then to set the exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next See Section 3 5 for more detailed instructions to change settings on the RDC2 If the battery is disconnected and reconnected during generator set maintenance or service the time date and exercise settings Will need to be re entered 3 6 2 This section explains how to change the exercise settings after the initial setup Changing the Exercise Settings Follow the pr
12. and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is clear Section 5 Scheduled Maintenance 69 5 7 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spiled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry
13. ee ne 13 Section 1 Descriptions and Service Views eeeeeeeeeeeee kaikas 15 lob INIOQUCHON amas kin kirai EE rr Eod Das QE d we Re oet sia I a ai f 15 12 ENOM Sussex vex dn x er b eiut do 15 1 3 Generator Set Enclosure x eese een a is Rab paca 15 UC MEE Udo Tcr a bee siert 15 1455 Transl S WILODL s kas oi bk el o oaa Cu ated M desta isn 15 1 6 S ONMOICKS Ats aco deduc iqr wed a D as ia dut eia dere 15 1 7 OnCue Plus Generator Management System 17 1 8 ACCO OE REESE a 8 oa Dinos TITLED 18 1 8 1 Garb retor Heater ass ee 18 1 8 2 Programmable Interface Module PIM ks 18 1 83 Load Control Module LCM kaka 18 1 9 4 kodd hed NIE ice ee ka r e dr LS 18 1 9 DEMOS VIEWS 5155 onc ra d xou vm rens kd eut Ed ads du dd d ee Sd 19 Section 2 Generator Set Operation cece eee nn nn nn nun enhn hn nnn 21 2 Prestant GDec RISE in e dodo bad c a en ea lo deed e soc ndi a n eR A eate oa 21 2 2 Exercising the Generator Set 0 aaa aaa aaa 23 2 3 Generator Set Operation anasa en Pa arae Lar d eS Dod 23 2 3 1 Local Starting and Stopping 23 52 1 ee S kn k aa a 23 2 3 2 Automatic Starting and Stopping lt ks 23 2 3 3 Remote Starting and Stopping 0 cc eens 23 2 34 Engine Start Crank Cycle lt a 23 235 ENGINE COooldOWLD av c win ika an i Dedi ho a a dudes 23 2 3 6 X Automatic Operation with Model RXT Transfer Switch 23 2 39 7 Automat
14. fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING e s eete e oe f 4 TT VARIA rasen Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on
15. oil needed to refill the engine may be less than the capacity shown in a Press the OFF button on the generator set Figure 5 2 Use the dipstick shown in Figure 5 1 controller to check the oil level during the fill Do not fill past l the full mark on the dipstick b Disconnect the utility power to the generator c Disconnect the generator set engine starting battery negative lead fist d Remove the side panel on the exhaust side of Figure 5 2 Engine Oil Capacity new dry engine the enclosure a See Section 5 2 3 for the recommended oil e Clean the area around the dipstick and oil fill type To prevent spilling use a funnel to add oil cap through the oil fill port Use the dipstickto check the oil level before starting to add the final quart f To prevent oil from spilling into the alternator of oil Fill the engine to the F mark on the completely cover the alternator with rags dipstick around the areas near the oil drain valve and oil filter b Reinstall the dipstick and the oil fill cap g Insertadrain tube 3 8 in inside diameter onto c Reconnect the generator set engine starting the oil drain valve and place the end of the tube battery negative lead last into a drain pan The tube will reduce the potential for spilled oil d Reconnect the utility power to the generator set h Open the oil drain valve on the engine e Press the RUN button on the generator set i Remove the dipstick and oil fill cap Allow time
16. set Hemove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 6880 8 14 The Model 8 10 12RESV L generators include a resettable thermostat in the air intake compartment The thermostat detects excess heat inside the enclosure Ifthethermostattrips the generator will shut down and the controller will display a fault underspeed underfrequency or undervoltage If the thermostat trips for some reason other than high temperature i e a nuisance trip folow these steps to reset the thermostat Procedure to Reset the Thermostat 1 Disconnect the utility power to the generator by opening turning OFF the corresponding circuit breaker at the building s distribution panel 2 Open the enclosure roof Ensure that the roof is secured with the roof stay on the left side of the enclosure 3 Remove the left
17. set to automatically run the generator set at the same time and day each week Exercising the generator set weekly is reguired to keep the engine and alternator in good operating condition A laptop computer with Kohler SiteTech software can be used to change the exercise freguency to every two weeks Use a USB cable to connect the controller to the computer and see TP 6701 SiteTech Operation Manual for instructions 4 5 1 Exercise Modes Unloaded Cycle or Loaded Full Speed exercises can be set from the DC2 controller The Unloaded Cycle exercise mode is the default exercise mode A Model RXT transfer switch is required for the Loaded Full Speed exercise mode See Section 2 4 for more information about the exercise modes A laptop computer with Kohler SiteTech software can be used to change the exercise mode to Unloaded Full Speed 4 5 2 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week Follow the procedure below to set the exerciser Procedure to Set the Exerciser 1 Press AUTO Verify that the AUTO LED is on and Utility power is available 2 Press the exercise button to start an unloaded exercise 3 Ifaloaded exercise is required press the Exercise button again within 5 seconds 4 After 5 seconds the generator begins its crank cycles During the crank cycles the number of the crank cycle is displayed No button presses are acknowledged during the cr
18. settings Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Voltage Regulator VR Voltage Adj The generator set voltage is factory set and typically does not require adjustment in the field If voltage adjustment is required contact a Kohler authorized distributor or dealer for service Refer to the generator set Installation Manual for instructions to adjust the voltage Setting the Exerciser Use the Genset System menus to set the generator set exerciser Refer to Section 2 4 for instructions to set the exerciser and for more information about exercising the generator set After a scheduled exercise run the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting Adjusting the Display Contrast To adjust the display contrast use the down arrow button to step to the Contrast menu Press the Select button and then use the up and down arrow buttons to adjust the contrast Press the Select button to save the contrast setting 42 Section 3 RDC2 Controller Operation Genset gt System Voltage System 240 V System Freq 60 Hz VR Voltage Adj 240 0V System Phase Single System Battery 12V Next Exercise 06 30p 15Dec2011 Exercise Mode Unloaded Variable
19. software SiteTech software is available to Kohler authorized distributors and dealers See TP 6701 SiteTech Software Operation Manual for more information 6 3 Fault Messages The RDC2 DC2 controller displays fault messages to aid in troubleshooting Selected fault messages and recommended checks are listed in Figure 2 3 TP 6880 8 14 Section 6 Troubleshooting Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 5 4 6 4 Circuit Protection If the generator set circuit breaker trips repeatedly contact an authorized Kohler distributor dealer for service 6 4 4 Controller Internal Circuit Protection The controller is equipped with internal circuit protection A fault message Accy PwrOver Warning or MainPwrOverL Shutdown is displayed if this internal protection is activated Press OFF to reset Contact an authorized Kohler distributor dealer for service 6 4 2 Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load If the circuit breaker trips reduce the load and switch the breaker back to the ON position 6 4 3 Auxiliary Winding Circuit Breaker A resettable circuit breaker protects the alternator The circuit breaker is located in the junction box area See Figure 1 2 Section 6 Troubleshooting 73 6 5 Troubleshooting Figure 6 1 contains generato
20. stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6880 8 14 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL DI EO DIN DIP DPDT DPST DS DVR cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer Copper Canadian Underwri
21. static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Section 2 Generator Set Operation 21 A 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
22. the area 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 itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases 70 Section 5 Scheduled Maintenance Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the te
23. the last event press the select button to return to the main menu Date MOJDAYEAR EventLog gt time HR MN event number W S I engine hours event name Date MO DA YEAR time HR MN event number W S I engine hours Press UP and Down arrow buttons to scroll through events event name Press Select button at any time to return to the main menu Figure 3 26 Event Log Section 3 RDC2 Controller Operation 53 Notes 54 Section 3 RDC2 Controller Operation TP 6880 8 14 Section 4 DC2 Controller Operation 41 DC2 Generator Set Transfer Switch Controller Model RESVL generator sets are eguipped with the DC2 generator set transfer switch controller Model RESV generator sets are equipped with the RDC2 generator set transfer switch controller See Section 3 for RDC2 controller operation information The DC2 controls the following power system components e Model 8RESVL 10RESVL or 12RESVL generator set e Model RXT Automatic Transfer Switch ATS e Load Control Module LCM or load shed kit 1 User Interface 2 USB port mini B see Section 6 2 GM77569 e Programmable Interface Module PIM Figure 4 1 DC2 Controls and Indicators DC2 controller features include e wo line x 16 character backlit digital display with adjustable contrast e OFF AUTO RUN and EXERCISE generator set control buttons 4 2 Controls and Indicators Figure 4 1 illustrates the DC2 controller See Figure 4 2 for
24. time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a shorttime Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of any building adjacent to the generator set Locate the detectors to adequately warn the buildings occupants of the presence of carbon monoxide Keep the detectors operational at all times
25. 008 The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes The LCM automatically manages up to six residential loads Four power relays are provided for management of non essential secondary loads and two relays are available to control two independent air conditioner loads The LCM is controlled by the RDC2 DC2 controller The load on the generator set is monitored and loads are added or shed in the order of their priority See specification sheet G6 120 and the LCM installation instructions for more information 18 Section 1 Descriptions and Service Views Load Shed Kit The optional Load Shed Kit functions in a similar fashion as the Load Control Module LCM and provides an automatic load management system to comply with section 702 5 of NEC 2008 The installer is responsible for ensuring that the power system installation complies with all applicable state and local codes 1 8 4 The Load Shed Kit automatically manages up to six residential loads four customer supplied power relays and two relays to control two independent air conditioner loads The Load Shed Kit is controlled by the RDC2 DC2 controller The load on the generator set is monitored and loads are added or shed in the order of their priority See specification sheet G11 124 and installation instructions TT 1609 for more information Either a Model RDT or Model RXT transfer switch is r
26. 1 TP 6880 8 14 List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Literature Type Part Number Installation Manual Model 8 10 12RESV RESVL Generator Set TP 6879 Operation Installation Manual Model RXT Automatic Transfer Switch TP 6807 Operation Installation Manual Model RDT Automatic Transfer Switch TP 6345 Installation Manual Model RSB Automatic Transfer Switch TP 6486 Operation Manual Model RSB Automatic Transfer Switch TP 6487 Operation Manual OnCue Plus Software TP 6928 Operation Manual SiteTech Software TP 6701 Installation Instructions Load Control Module LCM TT 1574 Installation Instructions Programmable Interface Module PIM TT 1584 Figure 2 Related Literature Introduction 11 Nameplate The following illustration shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces providedin the product information section on the inside front cover of this manual See the service views in Section 1 9 for the nameplate location KOHLER CO KOHLER WI USA SERIAL BUILD DATE MM YY FUEL PHASE KW KVA P F GEN MODEL BATT V INSUL NEMA CLASS _ 40 C AMB KW VARIES WITH BTU CONTENT OF FUEL Emission Information The Kohler Model SV620 engine used on the 8RES
27. 14 Introduction This manual provides operation and maintenance instructions for residential commercial model 8 10 12RESV and RESVL generator sets equipped with Kohler RDC2 or DC2 generator set transfer switch controllers See Figure 1 The RDC2 and DC2 controllers control the generator set and the optional Model RXT transfer switch This generator set is approved for use in stationary applications in locations served by a reliable utility power source Have the generator set installed by an authorized distributor dealer or service technician Refer to TP 6879 Installation Manual for installation instructions Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition RESV RESVL Generator Set Figure
28. 4 for information about the exercise modes 13 Set the exercise frequency weekly or every two weeks Weekly exercises are recommended 14 Press the down arrow button to step to the Return menu Press the Select button to return to the main menu After a scheduled exercise run the next exercise time and date will be updated automatically based on the Exercise Frequency setting Other transfer switches For a loaded exercise with a transfer switch other than a Kohler Model RXT ATS refer to the transfer switch operation manual for instructions Exerciser Reset To reset the exerciser to run at a different day and or time or to change the exercise mode follow the procedure in Section 3 6 2 to change the exerciser settings TP 6880 8 14 Genset gt System Freg System XX X Hz System Phase System Volt Battery V HOLD Next Exercise Next Exercise HR MN PM MM DD YY HR MN PM MM DD YY OLD O Exercise Mode IL Exercise Mode Loaded Unloaded Cycle Unloaded Full Loaded Full HOLD Exercise Freq Exercise Freq Weekly Weekly Bi Weekly lt Language jd Contrast 50 lt Return tp6804 f the exerciser has not been set No Exercise Sch will be displayed Figure 3 8 Procedure to Set the Exerciser on the RDC2 Controller TP 6880 8 14 Section 3 RDC2 Controller Operation 37 3 7 RDC2 Controller Menus Controller menus display power system information including stat
29. EXSIoISOr m k do a A SEE i debeas RU iua 36 3 6 1 Setting the Exerciser at Controller Power up Ls 36 3 6 2 Changing the Exercise Settings lt 36 TP 6880 8 14 Table of Contents Table of Contents continued 3 7 RDC2 Controller Menus Laika aaa aka 38 38 Man Men ar sa Stak otk nenne L ius aa i a a r a ii 38 39 OvervieWw MENU ce zz Cus siai ana Ak esM ee EE ee det ei bd 39 8 10 Engine Melenng Ie 145 aeu tees rode ede nU i ober r QE atq 39 3 11 Generator Metering Menu ccc cece mnn 40 3 12 Generator Set Information Menu 0 0 aaa 41 3 13 Genset Run Time Menu eeseeeeee nnn 41 3 14 Genset System Merl K tina pL EET e ra bowed i k ba qua 42 3 15 Alo Stalls MENU s 25 1a ede deed Do macb aat a I RO qa decas do bd 43 3 16 ATS Configuration Menu 0 ccc cece eee teen eens 44 3 17 Date and Time Menu 0 ccc aka aaa 45 3 18 Networking Information Menus 0c cece eee n nnn 45 3 18 1 Networking Status Submenu Lakis 46 3 18 2 Networking Configuration Submenu OnCue Plus Password 47 3 183 RBUS INIONMAION rar a aka ka ania ARE RARE 19 i ETI REC ne ed 49 3 18 4 Remote Devices Submenu 0 0 eee eens 50 3 19 Programmable Interface Module PIM Status Menu 0 00a ee 51 3 20 Load Control Module LCM or Load Shed Kit Menus 52 321i EVEN Kojo ar e ee eat E IE 53 section 4 DC2 Controller Operatlon un k kas
30. Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Section 5 Scheduled Maintenance 61 5 1 Scheduled Maintenance Refer to the following service schedules and the runtime hours displayed on the controller display to schedule routine maintenance Intervals are shown in hours of operation and or time intervals i e weekly monthly quarterly etc Have an authorized distributor dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units subjectto extreme weather long operating hours or dusty or dirty conditions more frequently Contact an author
31. Model RXT ATS interface board is connected e Battery voltage Battery voltage is checked before exercise to verify engine starting capability Battery voltage provides a measurement of battery health If the controller detects low battery voltage the condition is indicated on the display e Communication integrity tests J1939 RBUS Ethernet and USB are monitored for messages indicating that the controller and wiring are reliable e Engine speed Engine speed is measured at reduced speed and full speed An overspeed or underspeed condition will result in a fault condition and shutdown e Generator output frequency and voltage Operating the generator at full speed allows the RDC2 DC2 controller to check the output power for correct voltage frequency and stability When the engine is running at full speed the controller verifies that the voltage and frequency are within acceptable limits A fault message is displayed if the voltage or frequency is out of range e Oil pressure Oil pressure is verified to ensure proper lubrication of critical engine components Pressure is monitored at both reduced and full speeds If the oil pressure is low the Low Oil Pressure message is displayed and the generator set shuts down TP 6880 8 14 2 4 3 Unloaded Full Speed Exercise The unloaded full speed exercise runs the generator set atfull speed for 20 minutes withouttransferring the load To set an unloaded full speed exercise follow
32. Plus Built in 2 5 amp battery charger Remote two wire start stop capability for optional connection of Model RDT or RSB transfer switches Diagnostic messages o Displays diagnostic messages for the engine generator Model RXT transfer switch programmable interface module PIM and load control module LCM or load shed kit o Over 70 diagnostic messages can be displayed Maintenance reminders System settings o System voltage frequency and phase o Voltage adjustment o Measurement system English or metric ATS status Model RXT ATS required o Source availability o ATS position normal utility or emergency generator o Source voltage and frequency ATS control Model RXT ATS required o Source voltage and frequency settings o Engine start time delay o Transfer time delays o Voltage calibration o Fixed pickup and dropout settings Programmable Interface Module status displays PIM o Input status active inactive o Output status active inactive Load control module LCM or load shed kit menus o Load status o Test function TP 6880 8 14 DC2 Controller Features e Four button keypad OFF AUTO RUN and EXERCISE pushbuttons e LED indicators for OFF AUTO and RUN modes e LCD display o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility e Scrolling system status display o Generator set status o Voltage and frequency o Engine temperat
33. RDC2 Controller 1 Press the Select button to enter the main menu 2 Press the down arrow button until the desired menuis displayed See Figure 3 9 Date and Time are used for this example Press 3 Press the Select button to enter the Date and Time menu Date Press Display 05Dec2011 Overview gt Display 12h Date gt Display and Time 4 To change the date and time settings press the Select button again The year will flash Date Press Display 05Dec2011 5 Pressthe up or down arrow buttons to change the year i Date Press OR Display 05Dec2012 6 When the correct year is shown press the Select button The year is saved and the next setting month flashes Date Press Display 05Dec2012 7 Repeat steps 5 and 6 using the arrow and select buttons to set the month and the date Figure 3 7 Changing Settings TP 6880 8 14 8 When the correct date is shown press the Select button The saved date is shown Date Press Display 03Jan2012 9 Press the down arrow button to step to the next menu 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time Display Note To change from am to pm press the up arrow key to increase the hour until the correct hour and pm is displayed 11 In the time format menu press Select and then press the up or down arrow button to change the format 12 hr or 24 hr Press
34. TS Normal Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK Battery 12 3V Runtime 12345 6 h Next Exercise 7d 6h 42m OnCue Status Disconnected Sample data shown Model RXT ATS required OnCue status is displayed only if OnCue password has been reset Figure 4 5 Status Displays Generator Running TP 6880 8 14 Active Alert if any Genset State Standby Battery 12 3V Runtime 12345 6 h Next Exercise 7d 6h 42m Next Maint 123h or 12months OnCue Status Disconnected Sample data shown OnCue status is displayed only if OnCue password has been reset Figure 4 6 Status Displays Generator in Standby 4 3 Controller Power The DC2 controller is powered by the generator set engine starting battery Note To disconnect controller power disconnect the utility power to the generator set and disconnect the battery negative lead first 4 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The DC2 controller monitors the battery voltage and provides a constant 14 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz utility power provided from the building on a breaker protected circuit for the built in battery charger See the Installation Manual for instructions to connect power Section 4 DC2 Controller Operation 57 4 5 Exercise The DC2 controller can be
35. The OnCue Plus Generator Management System comes included with your generator and allows monitoring and control of your generator set from a personal computer smart phone or tablet OnCue Plus can be configured to send email or text message notifications in the event of a generator set fault See TP 6928 OnCue Plus Software Operation Manual for software instructions Section 1 Descriptions and Service Views 17 1 8 Accessories The following optional accessories are offered for the RESV and RESVL generator sets 1 8 1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C 82 F The carburetor heater prevents condensation and carburetor icing The heater requires a continuous source of 120 VAC power 1 8 2 Programmable Interface Module PIM The optional Programmable Interface Module PIM provides two programmable inputs and six programmable dry contact outputs for connection to customer supplied equipment The outputs are controlled by the RDC2 controller and can also be controlled remotely using the OnCue Plus program The PIM is mounted ina NEMA 3H aluminum enclosure which can be mounted indoors or outdoors See the installation instructions provided with the PIM 1 8 3 Load Control Module LCM The optional Load Control Module LCM provides an automatic load management system to comply with Section 702 5 of NEC 2
36. V RESVL generator set is certified to operate using natural gas or propane fuel The Kohler Model KT725 engine used on the 10RESV RESVL and 12RESV RESVL generator set is certified to operate using natural gas or propane fuel The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements Figure 3 provides the engine compliance period in hours associated with the category descriptor which may be found on the certification label Emission Compliance Period EPA Category C Category B Category A 250 hours 500 hours 1000 hours CARB Moderate Intermediate Extended 125 hours 250 hours 500 hours Figure 3 Emission Compliance Period 12 Introduction Refer to the certification label for engine displacement The exhaust emission control system for the SV620 engines 8RESV RESVL is EM for U S EPA California and Europe The exhaust emission control system for the KT725 engine 10RESV RESVL and 12RESV RESVL is EM for U S EPA California and Europe Generator Set Application Kohler Power Systems KPS ensures that all Kohler generator sets are certified to applicable standards for their intended application It is the owner operator s responsibility to operate Kohler generator sets exclusively according to the directions provided in the accompanying operation manuals Kohler gene
37. a eee r a Red 55 4 1 DC2 Generator Set Transfer Switch Controller anaana c eee ees 55 4 2 Controls and Indicators usus care wes 2 ea EES Gee ERES 55 4 2 1 Controller Keypad a5 sese I beta a aa en 56 4 2 2 PET ndicatOer9 eau re Ber a a aa 56 We EODD reset EI ene area gine ee ee 57 4 3 Controler POWOIL4 vcr ortho 5 ludi I eoo ended e n beds wns be Mer ew 57 4 4 Battery Charging aaa ec III mn 57 Wi SEREIEISO ss Er saweee a 58 4 5 1 Exercise Modes 1 35 9 5 1E a hha ea 58 4 5 2 Setting the Exerciser Lakis 58 4 5 3 Exerciser Resel fetid od D eed aks Wb UE ed d dde oe ae iud 58 2 0 inia ojo S eroe ee AUS 58 4 7 Maintenance TImer 2 issinaleneireRidvteme amp ee x RE e Gua Xue qe RA WO eek Bars 59 4 8 On amp ue Pl s PassWord vu ne 00 had si xd Y dac DER deter 59 Section 5 Scheduled Maintenance Lada i aaa eee eee eee ee ee nenn nn nn nnn 61 5 1 Scheduled Maintenance 4 aks r eee ae a a a Ea 62 5 1 1 Service schedule sisse ane RE Roh at o a AE 63 5 2 EUBLIEAUON SYSIem A qui ot Rl M ee uai urbc dos a a a da Owe nsa 64 5 2 1 Low Oil Pressure Shutdown 0 00 cece cee eee eens 64 5 22 Ol CHCCK251 conrsnrerasetoeidesid ais daiva 205 Sa Rees 64 5 2 3 Engine Oil Recommendation 0 0 cee eee eee eee 64 5 2 4 Oil Change Procedure ccc cece eee nennen nennen 64 5 2 5 Resetting the Maintenance Timer eee eens 66 SK MEME ecd E sch ook teh kak IE E eure eee ai e
38. an cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery
39. ank cycles 5 The generator runs through the exercise cycle described in Section 2 4 2 The controller monitors the system during the unloaded exercise as described in System Diagnostics 6 After 20 minutes the engine stops automatically The exercise time is set to the time the exercise button is pressed An unloaded or loaded exercise as selected above will occur at the same time every seven days 58 Section 4 DC2 Controller Operation 4 5 3 Exerciser Reset To reset the exerciser to run at a different day and or time follow the procedure in Section 4 5 2 to enter the new exerciser settings The old settings will be replaced by the new time and day 4 6 Event Log The event log displays up to 10 controller faults and notices starting with the most recent event Events are numbered 1 10 with 1 being the most recent Each event is displayed with the date and time of the event the number of the event a letter to indicate whether the event was a warning W shutdown S or informational notice I the engine hours at the time of the event and the event description See Figure 4 7 Hold Any Screen OFF Event number W S I engine hours Event name Press OFF Event number W S I engine hours Event name Press AUTO button at any time to exit the event log Figure 4 7 Event Log Procedure to View Event Log 1 Press the OFF button The controller must be OFF to display the event log 2 Press and hold the
40. arbon monoxide detectors according to the manufacturer s instructions TP 6880 8 14 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 Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention ifthe condition of affected persons does not improve within minutes of breathing fresh air A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components for cracks leaks
41. are displayed No changes are allowed from this menu Eng Runtime displays the total number of hours that the generator set engine has run The runtime is not resettable The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required The estimated date for the next scheduled maintenance is also displayed The maintenance reminder intervals are based on the engine manufacturer s recommendation for changing the oil Refer to Section 5 Scheduled Maintenance for maintenance instructions After changing the oil and performing other recommended maintenance go to the Overview menu to reset the maintenance timer See Section 5 2 5 for instructions to reset the maintenance timer a cour LO Eng Runtime 12345 6 h Run Time Eng Starts 123456 Next Maintenance 150 h or Mar2012 lt Return Note Sample data shown Figure 3 14 Generator Set Run Time Menu Section 3 RDC2 Controller Operation 41 3 14 Genset System Menu The genset system menu displays the system information shown in Figure 3 15 Generator sets are factory set and should not require changes to the system settings in the field A Kohler authorized distributor or dealer can adjust these settings if necessary If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason see Section 3 5 for instructions to enable editing and change the system
42. arged atthe exhaust outlet Seethe service view in Section 1 9 for air intake and exhaust locations To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above them Overheating and severe generator damage may occur 5 6 Exhaust System A WARNING wate es PEE x T ED a sen Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a shorttime Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of any building adjacent to the generator set Locate the detectors to adeguately warn the buildings occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the c
43. 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 Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Gh 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 8 Safety Precautions and Instructions Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or
44. ble of Contents Notes TP 6880 8 14 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical eguipment 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 This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6880 8 14 Accidental Starting A WARNING Accidental starting C
45. controller The generator set will start for the engine oil to drain completely f Run the generator set for a minute to allow the j Close the oil drain valve and remove the oil oil pressure to reach operating range drain tube g Stopthe generator set wait 1 minute and then k Replace the dipstick recheck the oil level Add oil to bring the levelup 2 Replace the oil filter to the F mark on the dipstick 4 Check for leaks a Clean the area around the oil filter a Check for oil leaks b Loosen the oil filter by rotating it counterclockwise with an oil filter wrench b Fixleaks and recheck the oil level C As you remove the oil filter tilt the filter upward c Reinstall the side panel to prevent oil from spilling 5 Reset the maintenance timer on the controller d Clean the gasket sealing surface of the oil filter adapter TP 6880 8 14 Section 5 Scheduled Maintenance 65 5 2 5 Resetting the Maintenance Timer Model RESV RDC2 1 From the Overview menu step down to the Genset Run Time menu Press the Select button and then step down to the Next Maintenance screen Press the Select button Press the Up arrow button so that Reset Maint Timer Yes is displayed Press the Select button After about two minutes the new maintenance interval and date are displayed Model RESVL DC2 1 Press and hold the OFF and AUTO buttons together until Maintenance Timer Reset is dis
46. d equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions 9 Welding on the generator set Can cause severe electrical eguipment 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 battery charging alternator connections 5 Attach the weld ground connection close to the weld location Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardou
47. details of the controller s user interface 2 line LCD display EXERCISE button RUN button and LED OFF button and LED AUTO button and LED Figure 4 2 DC2 User Interface TP 6880 8 14 Section 4 DC2 Controller Operation 55 4 2 1 Controller Keypad 4 2 2 LED Indicators TheRUN OFF and AUTO buttons controlthe generator LEDs above the RUN OFF and AUTO buttons indicate set as described in Figure 4 3 the mode of operation as shown in Figure 4 4 Use the EXERCISE button to set the exerciser on the DC2 controller See Section 4 5 for instructions to setthe exerciser Note A personal computer laptop with Kohler SiteTech software is required for changing settings on the DC2 controller Button Button Function RUN Press to start the generator set The engine start time delay is ignored The software version and engine model are displayed briefly when RUN is pressed Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press to clear faults and reset the controller Press and hold to access the event log Press to place the generator set in Automatic standby mode Press to exit the event log Press and hold AUTO and OFF to reset the maintenance timer EXERCISE When the controller is in AUTO mode press to set the exerciser See Section 4 5 When the controller is OFF press and hold to reset the OnCue password See Section 4 8 Fig
48. dicate which source is supplying power to the building based on the position of the RXT transfer switch See Figure 3 2 and Figure 3 4 Note The power system LEDs operate only if a Model RXT transfer switch is connected They will not operate if a different transfer switch is used Button Button Function Starts the generator set The engine start time delay is ignored OFF Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press OFF to clear faults and reset the controller AUTO Down arrow Select Places the generator set in Automatic standby mode Use to navigate through menus and change settings This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller Up arrow Figure 3 3 RDC2 Controller Pushbutton Operation RUN Lights when the generator set has been started locally by pressing the RUN button Remote start and stop commands are ignored OFF Lights for 2 seconds then flashes every 2 seconds when the generator set and controller are off Remote start stop commands have no effect The exercise cycle will not run In Auto mode OFF LED flashes quickly to indicate a fault shutdown Attention required Identify and correct the fault condition before resetting the controller Lights when the generator is in automatic standby mode Generator set will respond to engine start a
49. e tool in a secure location TP 6880 8 14 Descriptions and Service Views 1 4 Alternator The generator uses Kohler s unique PowerBoost voltage regulation system which provides instant response to load changes PowerBoost ensures reliable motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 5 Transfer Switch The RDC2 and DC2 controllers are designed to interface with and control the Kohler Model RXT Automatic Transfer Switch ATS Do not use the Kohler Model RRT transfer switch with the RDC2 or DC2 controller lf the power system uses a different model transfer switch the RDC2 and DC2 controllers will not control the transfer switch An ATS other than the Model RXT must be equipped with a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set 1 6 Controllers RESV models are equipped with the RDC2 RESVL models use the DC2 See Figure 1 1 The controller provides integrated control for the generator set Kohler Model RXT transfer switch programmable interface module PIM and load control module LCM or load shed kit RDC2 RESV DC2 RESVL Figure 1 1 Controllers Section 1 Descriptions and Service Views 15 The controller s 2 line LCD screen displays status messages and system settings
50. each level of any building adjacent to the generator set Locate the detectors to adequately warn the buildings occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon 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 Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TP 6880 8 14 Fuel System A WARNING JH W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe inj
51. ed and serviced by qualified electrical personnel The voltage calibration mode can be entered from the Generator Metering menu Contact a Kohler authorized distributor dealer for service The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration if necessary See Figure 3 12 Generator gt Metering Three phase slide phase Volts L1 L2 Volts Note Actual settings may vary 240 V 240 V Volts L2 L3 Frequency 240 V 60 0 Hz Volts L3 L1 240 V Frequency 6 OHz ME Reset Calib No Reset Calibration lt Return Calib Yes tp6810 Figure 3 12 Generator Metering Menu 40 Section 3 RDC2 Controller Operation TP 6880 8 14 3 12 Generator Set Information Menu The generator set model number and serial numbers are displayed No changes are allowed from this menu Model and serial numbers are factory set and should not reguire changes in the field except in the event that the controller is being replaced A personal computer running Kohler Site Tech software is reguired to enter the generator set model number and serial numbers on a replacement controller Contact an authorized Kohler distributor dealer for service Information 20RESV Genset S N HHHHHHHH Controller S N HHHHHHHH lt Return tp6804 Figure 3 13 Generator Set Information Menu TP 6880 8 14 3 13 Genset Run Time Menu The data shown in Figure 3 14
52. ee peeks a A Sa EREA 66 5 4 Air Cleaner Service 1 39 1 4 aria pawn ead deat pube ved 9 E SE uos 67 5 4 1 Air Cleaner 8RESV RESVL Models seen 67 5 4 2 Air Cleaner 10 12RESV RESVL Models es seen 68 5 5 GOONG oVSLelTi auos epe I doc CHER dopo Uv api quu etr S iu 69 5 6 Exhaust SYSTEM es sedare ae pace para dec c ao XQ oae Udo Rea Plc Rar 69 o Wael it elegance arcantegume ees ce lene ra Metu Let ica 70 5 8 Storage Procedure ccs oie nv is is ea la 71 5 8 1 LubricatiAig System 25223 2 4 m dl RE ORCI Ren OS hele bay Valea eae 71 S62 WEUChSVSIOM grate kas coe es a ai E a a a aa dio en 71 5 9 9 Oylihder BUbriealloni ru ei re 71 Table of Contents TP 6880 8 14 Table of Contents continued 5 8 4 Exterior Preparation 00 ccc ccc eee mm 71 555 Ballery sa aces eee ass bat ah oie S keene o a a 71 Sectlon 6 Troubleshooting 52 4 E ERE i RE an a i a 73 Gali AMMOGUCTION us kais s oet cae a d i A Ed ERE 73 62 USB POM SL i ios k east 73 6 3 Eault Messages an aaa ann ru EE a P x 73 64 Cret Proteco errean a od tet S roles og poe e vis a a a lo Se S vd tha 73 6 4 1 Controller Internal Circuit Protection lt 73 6 42 Line Circuit Breaker lleleeseeee nnn 73 6 4 3 Auxiliary Winding Circuit Breakers 73 65 LTOUDIESNEOING siu bene aes dip E Mete T PERPE b sande ae eae heran 74 Appendix A JADDFeVISUOFIS seemet decan eeu re Mac Xo Re T dne CR AE eC A 75 TP 6880 8 14 Ta
53. equired for the load shed kit installation The load shed kit mounts inside the Model RDT or Model RXT transfer switch enclosure and is available for single phase generators sets only Note Do not install both a load shed kit and a load control module LCM on the same system TP 6880 8 14 1 9 Service Views Hinged roof Air cleaner Nameplate location Thermostat Engine starting battery location battery purchased separately Gas regulator assembly and fuel selector valve Fuel solenoid valve Fuel inlet Field connection terminal block and 20 amp resettable circuit breaker behind panel COOL OC G EO0O0N Figure 1 2 Service View TP 6880 8 14 10 11 12 13 14 15 17 18 19 ADV 8539 Line circuit breaker 120 VAC receptacles for optional carburetor heater not shown Lock Locking tool provided with generator set USB port RDC2 or DC2 controller Oil check dipstick and oil fill Oil drain valve Oil filter Muffler Section 1 Descriptions and Service Views 19 20 Lifting holes 22 Exhaust outlet 21 Air intake Figure 1 3 Service View 20 Section 1 Descriptions and Service Views TP 6880 8 14 Section 2 Generator Set Operation 2 1 Prestart Checklist A WARNING Can cause severe injury or death Accidental starting Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the batte
54. er keypad If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is required then the IP parameters can be modified For applications that reguire static IP addresses press and hold the select button to enable editing disable DHCP and then step to the next parameters and enter the information If an error occurs while setting a parameter an error message is displayed and then the controller exits the edit mode Previous settings are preserved Section 3 RDC2 Controller Operation 47 Networking gt Networking gt Status Information HOLD Reset OnCue Password No A UP arrow for YES Down arrow for NO Reset OnCue Password Yes S N 1234567 New PW 12345 Reset OnCue Password RBUS gt Information or NO as displayed New password is displayed for Press Select to enter YES approximately 10 seconds HOLD DHCP DHCP Enabled Disabled UP arrow to enable Down arrow to disable IP Address 123 456 789 123 Subnet Mask 123 456 789 123 Gateway 123 456 789 123 DNS 1 123 456 789 123 DNS 2 tp6804 Figure 3 21 Network Configuration Submenu 48 Section 3 RDC2 Controller Operation TP 6880 8 14 3 18 3 RBUS Information e Model RXT transfer switch The RBUS Information menu contains settings for e Programmable Interface Module PIM remote modules that communicate with the RDC2 controller using RBUS pr
55. g with write only without weight transformer TP 6880 8 14 TP 6880 8 14 2014 by Kohler Co All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 Kohler Power Systems Asia Pacific Headguarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 For the nearest KOHLER authorized installation service and sales dealer in the US and Canada Call 1 800 544 2444 or visit KOHLERPower com
56. heck The generator set is shipped with oil Before operating the generator set check the engine oil in the crankcase To check the oil level shut down the generator set and wait several minutes Remove the dipstick and wipe the end clean reinsert and remove See Figure 5 1 Maintain the oil level between the Add and Full marks on the dipstick Add 5W 30 synthetic oil when the oil level is low Check the oil level before each use For extended operation check the oil level every 8 hours Do not check the oil level when the generator set is running 1 Oil Dipstick Oil Fill 2 Oil Drain Valve Figure 5 1 Oil Check typical 64 Section 5 Scheduled Maintenance 5 2 3 Engine Oil Recommendation Use 5W 30 API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner 5 2 4 Oil Change Procedure A WARNING a Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset
57. ic surfaces to prevent rust and corrosion Battery Perform battery storage last 1 Press the OFF button on the generator set controller Disconnect the battery negative lead first Clean the battery Place the battery in a warm dry location Connect the battery to a float equalize battery charger or charge the battery monthly using a trickle charger Follow the battery charger manufacturer s recommendations Section 5 Scheduled Maintenance 71 Notes 72 Section 5 Scheduled Maintenance TP 6880 8 14 6 1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems First check for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes of the problem and recommended corrective actions If the procedures in this manual do not explain how to correct the problem contact an authorized Kohler distributor dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to equipment 6 2 USB Port A USB port is located on the front of the controller See Figure 1 2 for location Use a USB cable with a mini B connector to connect the controller to your personal computer laptop Some controller settings can be adjusted using a laptop computer with Kohler9 SiteTech
58. ic Operation with Other Transfer Switches 24 PA EXE CISC bus i ai Ri Na a ak iu RUM d r 24 2 4 1 Setting the Exerciser Ausesin ien di d dices vovv dort v ia bt e 24 2 4 2 Unloaded Cycle Exercise with Complete System Diagnostics 24 2 4 8 Unloaded Full Speed Exercise 0c ccc ee eens 25 2 44 Loaded Full Speed Exercise with RXT only 00000e 25 2 4 5 Power Failure During Exercise Cycle seen 25 2 5 FAUS Anas siu a te asi EU Gl qa eee ice een 26 2 5 1 M cigar ka ota xian as od bea ele Baie eae ted tees ea Gas 26 252 SMULGOWNS Ls toh see tar Seu o aa afa US ai wd e Poe ate eis 26 2 5 3 ATS Communication Errors 0 0 0 ccc ee eens 26 2 5 4 Resetting the Controller after a Fault Shutdown 26 2 6 Generator Enclosure Thermostat annasan kaka 29 Section 3 RDC2 Controller Operation aaa cee eens 31 3 1 RDC2 Generator Set Transfer Switch Controller 00 0000 cee ae 31 3 2 Controls and Indicators za a Der io ai nae Sto warn a Pao ere a 31 3 2 1 Controller Keypad Atis Kaas La ss denen came ces as 32 3 2 2 EED IMNGIGAIONS 1 2 5 e ki oe ka r a eee es a L a ee eae Adan d sa 32 32 3 ECD DISDIAY ki k ikk iki iks Linus ide tame mee a a beeen 33 3 3 Controler POWER s Stant u hist T ee Eo a a de qe de rede 34 3 4 Battery Charging idek kas ces see die a a e nn 34 3 5 GHandging Selings asien asian 34 3 6 Seting The
59. ion 27 W or lt a SD Condition Check Frequency High SD Governed frequency exceeds 110 of the Contact an authorized system s frequency setpoint for more than 10 distributor dealer for service seconds Function becomes active 10 seconds after engine start 10 second inhibit Frequency Low Governed frequency falls below 90 of the Reduce the load and restart the system frequency setting for more than generator set 10 seconds or 1 Hz below the system frequency Contact an authorized setting for more than 60 seconds distributor dealer for service Function becomes active 10 seconds after engine start 10 second inhibit Lo Crank VIt Low cranking voltage Battery voltage falls below Charge or replace the battery 8 VDC for more than 6 seconds while the starter is engaged MainPwrOverL _ Oil Pres Low SD The LOP switch indicates low oil pressure for Check for leaks in the lubrication more than 5 seconds Function becomes active system ud un after crank disconnect 30 second Ghecttheoltevalandaddoilifthe inhibit level is low Note The low oil pressure shutdown does not Check the oil pressure switch and protect against low oil level Check the engine oil NUITS level regularly as recommended in Section 5 g Main power overload An over current fault on Contact an authorized the 70 controller power output short circuit distributor dealer for service Check for shorted run relay Chec
60. ir cleaner element 3 Element cover 4 Air cleaner knob 586536 Figure 5 6 Air Cleaner Components Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions TP 6880 8 14 Press the OFF button on the generator set controller Disconnect the utility power to the generator set Disconnect the generator set engine starting battery negative lead first Loosen the cover retaining knobs and remove the Cover Remove the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element Replace the element if it is dirty bent or damaged Check the air cleaner base Make sure it is secure and not bent or damaged Also check the element cover for damage and fit Replace all damaged air cleaner components Remove any loose dirt or debris from the air cleaner base Wipe the base carefully so that no dirt drops into the intake throat Check the condition of
61. ized distributor dealer for parts 62 Section 5 Scheduled Maintenance TP 6880 8 14 5 1 1 Service Schedule Procedure See PEE System Component or Procedure ETE A c 2 r 1 num Min tank suppy Ievai TT ee A a T Oil level 8 NE Or before use Crankcase breather hose Yearly or 500 hours or 500 Yearly or 500 hours Change oi m Yearly or 100 hours Replace filter ERES Yearly or 100 hours EE a a EE MEE x x Ense I 44 liu 14 RR RE Sa Nea T Eo or combustible materials near 3 EEE outlet DC Electrical System Battery charger operation charge rate if equipped ic Monthly Remove corrosion clean and dry battery and rack X Yearly Clean and tighten battery terminals and inspect boots Yearly Battery Pe O Battery electrolyte level and specific gravity and Battery electrolyte level and specific gravity gravity Yay Fr iii i S i i E G TTT ay t AL iii ia T Vebewerordemge O OO X Qmev m o LT TT T 1 ox Lx ee Wire cable insulation condition cable insulation condition 3 Years or 500 hours Eee i i E EB WeMy Air cleaner service Yearly or hours shown Spark plugs apply anti seize lubricant for easy removal Yearly or 500 hours Have valve lash checked adjusted 8RESV L DL dL EL E I 100 hours Have valve lash checked adjusted 10 1 E I 500 hours Replace s
62. k wiring for short circuits The generator set is not in Automatic standby Press AUTO to place the generator mode Remote start and stop commands from a set in Automatic mode when transfer switch or remote switch will be ignored appropriate Over Crank Three unsuccessful starting attempts Check the fuel supply spark plug and battery Check for loose connections Contact an authorized distributor dealer for service Engine speed sensor has failed or engine Contact an authorized stalled distributor dealer for service Measured load is greater than 102 of the Reduce the load generator set power rating for more than 1 minute 10RESV and 12RESV only Generator voltage high Output voltage exceeds Contact an authorized 120 of the system nominal voltage for more distributor dealer for service Spd Sens Fit Total Power High Volts L1 L2 High than 2 seconds Volts L1 L2 Low Generator voltage low Output voltage falls Reduce the load and restart the below 80 of the nominal system voltage for generator set more than 10 seconds Contact an authorized distributor dealer for service Engine cooldown runs before shutting down Figure 2 3 Controller Fault Messages 28 Section 2 Generator Set Operation TP 6880 8 14 2 6 Generator Enclosure Thermostat A WARNING o Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator
63. l and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams and drawings from your local distributor dealer 1 2 Engine The 8RESV generator set has a four cycle single cylinder air cooled Kohler engine and 10 12RESV generator sets have a four cycle twin cylinder air cooled Kohler engine The engines operate on clean burning natural gas or LPG Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Dependable maintenance free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LPG and vice versa while maintaining EPA emission certification 1 3 Generator Set Enclosure The generator set is housed ina steel enclosure which is dipped in e coat for extra corrosion protection and painted with a durable powder coat finish The enclosure has a hinged locking roof that allows easy access to the generator set controller when required but locks securely to prevent unauthorized access To open the roof insert the tool provided with the enclosure and turn counterclockwise 1 4 turn Then just raise the roof The roof stays open until you are ready to close it Be sure to close and lock the enclosure and keep th
64. low an acceptable level the controller starts the engine start time delay 2 If the utility source is not restored before the time delay expires the generator set starts 3 After the Normal to Emergency time delay the ATS is signaled to transfer the load to the emergency source Automatic Stop with Engine Cooldown 1 When the utility source is restored the Emergency to Normal time delay starts 2 When the Emergency to Normal time delay expires the load is transferred to the utility 3 The generator set runs through the engine cooldown cycle and then stops Section 2 Generator Set Operation 23 2 3 7 Automatic Operation with Other Transfer Switches Ifatransfer switch other than the Model RXT such as a Kohler Model RDT or RSB is used the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set The controller must be in AUTO mode to respond to remote start stop signals from an ATS or remote switch Press the AUTO button to put the controller into automatic mode Automatic Start The engine start contacts on the ATS close to signal the generator set to start and remain closed while the generator set is running Automatic Stop The engine start contacts on the ATS open to signal the generator set to stop 2 4 Exercise The RDC2 and DC2 controllers can be set to automatically run the generator set atthe same time and day each week Exercising the generator se
65. n 4 5 for instructions to set the exerciser on the DC2 2 4 2 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded exercise runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the default exercise setting The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 2 1 and described below e Runs at reduced speed for 10 minutes to warm up and exercise the engine e Ramps up and runs at full speed for 3 minutes Engine diagnostics are performed during this full speed portion of the cycle which provides the best test of engine and alternator power backup capability Diagnostic tests at full speed can identify potential problems with the power output and alert the operator before an emergency event e Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically 0 r oO D D Q N o D c LLI Engine Full Speed Cooldown Exercise Diagnostics Figure 2 1 Unloaded Exercise Cycle TP 6880 8 14 System Diagnostics During the unloaded exercise the controller monitors the following data The controller display indicates that the generator set is running unless afault is detected as described below e ATS connection The controller verifies that the
66. nd stop commands from the controller for example exercise start and stop commands or an ATS Time delays operate as described in Section 2 3 Utility Power Available Lights when utility power is available Building on Utility Power Generator Power Available Building on Generator Power Lights when the building load is connected to utility power through the RXT transfer switch Lights when generator power is available Lights when the building load is connected to generator power through the RXT transfer switch These LEDs operate only if aModel RXT transfer switch is connected Figure 3 4 RDC2 Controller LED Operation 32 Section 3 RDC2 Controller Operation TP 6880 8 14 3 2 3 LCD Display The controller is eguipped with a two line x 16 character backlit digital display with adjustable contrast When the generator is running the controller automatically scrolls through the displays shown in Figure 3 5 When the system is in AUTO the screens shown in Figure 3 6 are displayed When a fault or warning condition exists the controller will show the corresponding message See Section 2 5 for more information about faults Controller menus display power system information including status information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings See Sections 3 7 through 3 21 for menu diagrams Active Aler
67. nds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram Appendix 75 kg cm2 kgm kg m kHz kJ km kOhm kt2 kPa kph kV kVA kVAR kW kWh man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kil
68. ocedure below and see the flowchart in Figure 3 8 to set the exercise time and date mode and frequency Procedure to Set the Exerciser 1 Press the AUTO button on the controller 2 Press the Select button to go to the main menu See Figure 3 9 3 Press the down arrow button to step to the Genset System menu 4 Press the Select button to enter the Genset system menu See Figure 3 8 5 Use the down arrow button to step to the Next Exercise menu If the exerciser is not set No Exercise Scheduled will be displayed 6 Press and HOLD the Select button to enable editing 36 Section 3 RDC2 Controller Operation 7 Press the Select button The setting flashes to show that it can be changed For example HR flashes to show that the hour can be changed 8 Press the Up or Down arrow buttons to change the setting 9 Press the Select button to save the setting and move to the next For example save HR setting and move to MN 10 Repeat steps 5 through 9 to change the next item on the line until the desired settings are displayed 11 Press Select to save after all settings have been selected Settings will stop flashing 12 Ifthe generator setis connected to a Kohler Model RXT transfer switch the exercise can be changed to a loaded exercise Set the Exercise Mode to Unloaded Cycle Unloaded Full or Loaded Full RXT ATS required as shown in Figure 3 8 Unloaded Cycle is recommended See Sections 2 4 2 through 2 4
69. ode Press the RUN button to start the engine or press AUTO to allow remote starting Remote stop command received from a remote Check the remote switch position Check OnCue Plus switch ATS or OnCue Plus Engine malfunction Contact an authorized Kohler distributor dealer Figure 6 1 General Troubleshooting Chart 74 Section 6 Troubleshooting TP 6880 8 14 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 CG CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required as requested as supplied as
70. ontinued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Exhaust System Check for exhaust leaks and blockages Check the muffler condition e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e Checkfor corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed Oil Level Check the oil level before starting the generator set and at the intervals given in Section 5 Scheduled Maintenance Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set TP 6880 8 14 2 2 Exercising the Generator Set Operate the generator set without load once each week for 20 Minutes See Section 2 4 for information about loaded and unloaded exercise mode
71. or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 7 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 Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe
72. ore removing the generator set from service for three months or longer Follow the engine manufacturer s recommendations for storage if available Note Run the generator set monthly whenever 5 8 1 1 5 8 2 1 2 possible Lubricating System Operate the generator set until it reaches operating temperature or about 15 minutes Stop the generator set While the engine is still warm drain the engine lubrication oil from the engine crankcase Refill engine crankcase with oil See Section 5 2 3 for oil recommendations Run the generator set for a few minutes to distribute the clean oil Stop the generator set Fuel System Start the generator set With the generator set running shut off the gas supply Run the generator set until the engine stops Press the OFF button on the generator set controller TP 6880 8 14 5 8 3 Cylinder Lubrication B 2 5 8 4 1 2 5 8 5 Remove the spark plugs Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs Crank the engine two or three revolutions to lubricate the cylinders Exterior Preparation Clean the exterior surface of the generator set Seal all openings in the engine with nonabsorbent adhesive tape Mask all areas to be used for electrical contact Spread a light film of oil over unpainted metall
73. otocol This includes the e Load Control Module LCM or load shed kit following optional modules Networking gt Networking gt Information Status Networking gt Configuration RBUS rede Modules Connected Information 2 Devices See Figure 3 23 Net Cycle Time 123ms Module Timeouts 1234 Module Errors 1234 Figure 3 22 RBUS Information Submenu TP 6880 8 14 Section 3 RDC2 Controller Operation 49 3 18 4 Remote Devices Submenu The serial numbers for the PIM and LCM or load shed kit are printed on the circuit boards inside the enclosures Check the status of remote devices communicating through RBUS Device types can include e Model RXT ATS e Programmable Interface Module PIM e Load Control Module LCM or load shed kit From Figure 3 22 Remote gt Devices S N XXXXXXXXX S N XXXXXXXXX Return lt lt DeviceType gt gt lt lt DeviceType gt gt Module Status Connected Comm Errors 12345 Comm Timeouts 12345 Module ID 12 Firmware Ver 122 Dis Connected a Ru ie date and time that the MM DD YY 12 12 evice was connected Disconnected Displays the last date and time of successful communication Figure 3 23 Remote Devices Submenu 50 Section 3 RDC2 Controller Operation TP 6880 8 14 3 19 Programmable Interface Module PIM Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface mod
74. our 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 Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6880 8 14 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Service Assistance 13 Notes 14 Service Assistance TP 6880 8 14 Section 1 1 1 Introduction The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator setservice manual engine operation manua
75. ovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 106 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm m amp 2millionm MOhm M22megohm MOV MPa mpg mph MS ms m sec mtg MTU MW mW ur N norm NA nat gas NBS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards 76 Appendix NC NEC NEMA NFPA ph 9 PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC gt gty R rad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot r
76. played 2 Release the OFF and AUTO buttons 66 Section 5 Scheduled Maintenance 5 3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable Check the spark plug gap using a wire feeler gauge See Figure 5 3 for the recommended spark plug gap Adjust the gap by carefully bending the ground electrode See Figure 5 4 and Figure 5 5 Foreasy removal apply alight coating of anti seize lubricant to the cleaned spark plug threads Wipe away any excess compound Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29 8 Nm 18 22 ft Ib Generator Set Model Spark Plug Gap 8 10 12RESV RESVL Figure 5 3 Spark Plug Gap 0 76 mm 0 030 in Figure 5 5 Adjusting the Spark Plug Gap TP 6880 8 14 5 4 Air Cleaner Service A WARNING Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 5 4 1 Air Cleaner 8RESV RESVL Models The engine has a replaceable high density paper air cleaner element See Figure 5 6 1 Air cleaner base 2 A
77. pm RS RTDs normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory RS 485 proprietary communications relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV SAE scfm SCR S Sec
78. r set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Possible Cause Corrective Action Controller Backlight turns off after about 1 minute with no Backlight will turn on when a button is pressed or the display activity generator set starts backlight is off Controller Low or no battery voltage Check connections display is off Check generator set battery See Figure 6 1 The generator Battery weak or dead Recharge or replace the battery set L not Battery connections reversed or poor Check the connections crank Fault shutdown Check the controller display for fault messages See Section 2 5 Correct the fault condition and reset the controller Generator set in the OFF mode Press the RUN button to start the engine or press AUTO to allow remote starting Gererator thermostat tripped For trips other than temperature nuisance trips reset the thermostat See Section 2 6 The generator Air cleaner clogged Clean and or replace the air cleaner set cranks but Battery weak or dead Recharge or replace the battery does not start i ien R starts hard Battery connection poor Clean and tighten the battery connections lacks power or Spark plug wire connection loose Check the spark plug wires operates Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if erratically necessary Fuel pressure insufficient Check the fuel
79. rator sets designated as Stationary Standby Emergency or Emergency Standby may only be operated for emergency power generation and for maintenance testing Emergency power generation is limited to power production when electric power from a local utility or the normal power source if the facility runs on its own power production is interrupted The US Clean Air Act explicitly prohibits using Emergency Standby generators as a primary electric power source regardless of whether a site is connected to the electrical grid Emergency Standby generators may NOT be used to power sites which are not connected to an electric utility The U S Clean Air Act authorizes owner operator fines of up to 3 750 per day of operation in violation of the generator set s certification Owners operators should familiarize themselves with and perform all testing maintenance notification reporting and record keeping as required by the Clean Air Act In most cases performance testing is not required if the generator is operated and maintained according to the operation manual However owners operators must retain maintenance records TP 6880 8 14 For professional advice on generator set power reguirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power Systems website at KOHLERPower com Look atthe labels and stickers on y
80. rk gt Information PIM gt Status Load gt Control Event Log gt ATS Configuration appears only if a Model RXT transfer switch is connected PIM Status appears only if a programmable interface module is connected Load Control appears only if a load control module LCM or load shed kit is connected Figure 3 9 RDC2 Main Menu 38 Section 3 RDC2 Controller Operation TP 6880 8 14 3 9 Overview Menu Overview gt Active Alert 1 2h if any Genset Status Standby Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK Engine Runtime 12345 6 h Date 02DEC2011 Time HR MNpm Next Exercise 09 00p 09Dec2011 Next Maintenance 150 h or Mar2012 SW Version 12 34 lt Return Note Actual settings may vary Figure 3 10 Overview Menu TP 6880 8 14 lt gt tp6804 3 10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3 11 This menu displays status information only No settings can be changed from this menu Engine gt Eng Speed Metering 3600 RPM Note Actual settings may vary Figure 3 11 Engine Metering Menu Section 3 RDC2 Controller Operation 39 3 11 Generator Metering Menu Voltage Calibration The generator metering menu displays the generator A DANGER voltage and frequency See Figure 3 12 Hazardous voltage Will cause severe injury or death This equipment must be install
81. rminals together Refer to this section for general battery information and maintenance Also consult the battery manufacturer s instructions for battery maintenance All generator set models use a negative ground with a 12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 5 8 for typical battery connections EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 5 8 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease TP 6880 8 14 5 8 Storage Procedure Perform the following storage procedure bef
82. ry Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 6880 8 14 A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger Cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery 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 itis charging Donot dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge
83. s For instructions to set the exerciser see e Section 3 6 forthe RDC2 controller e Section 4 5 forthe DC2 controller 2 3 Generator Set Operation 2 3 1 Local Starting and Stopping Start Press the RUN button to immediately start the generator set Stop Press the OFF button The engine stops Run the generator set with no load for atleast2 minutes to ensure adequate engine cooldown 2 3 2 Automatic Starting and Stopping An automatic transfer switch monitors the utility power and signals the generator set to start when utility power is lost The ATS then transfers the load to the generator set When utility power is restored the transfer switch transfers the load back to utility runs the generator set with no load to cool down the engine and then stops the generator set 2 3 8 Remote Starting and Stopping A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set Close the switch to start and run the generator set Open the switch to stop the generator set Run the generator set with no load for atleast 2 minutes to ensure adequate engine cooldown 2 3 4 Engine Start Crank Cycle The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault See Section 2 5 Cranking 1 2 and 3 are displayed during the crank cycle
84. s In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Procedure to Change Settings 1 Press the Select button to enter the main menu 2 Pressthe down arrow button until the desired menu is displayed The Genset System menu is used for this example See Figure 3 9 3 Pressthe Select button to enter the genset system displays See Figure 3 7 4 Press the down arrow button to step through the generator set system settings 5 To change any ofthe genset system settings press the Select button The selected setting flashes 6 Press the up or down arrow buttons to increase or decrease the setting 7 When the desired setting is shown press Select The value stops flashing If there are additional adjustable settings on the screen the next setting flashes For example in the date menu the day month and year can be adjusted 8 Repeat steps 6 and 7 for each setting on the screen 9 Press the down arrow to step to the next screen 10 To exit press the down arrow button until Return is displayed Press the Select button to exit the menu 11 Press the AUTO or OFF button to exit the main menu Note If no buttons are pushed the controller exits the menus and returns to the generator set status display after 5 minutes TP 6880 8 14 Changing Settings on the
85. s Menu with Calibration TP 6880 8 14 Section 3 RDC2 Controller Operation 43 3 16 ATS Configuration Menu Note The ATS Configuration menu appears only if a Model RXT transfer switch is connected Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays and change the settings if necessary Changing ATS Configuration Settings To enable editing press the select button The value flashes to indicate that it can be changed Press the up and down arrow buttons to change the value Press the Select button to save the value shown Use the up and down arrow buttons to move to the next value to be changed Repeat the adjustment process until all values are correct Press the down arrow until Return is displayed Press the select button to return to the Main menu 44 Section 3 RDC2 Controller Operation Normal Freq 12 3 HZ ATS gt Configuration Normal Voltage 12345 6 V Emerg Freg 12 3 Hz Emerg Voltage 12345 6 V Emerg Engine Start 3 sec Transfer From 3 sec Normal Transfer From Emerg 120 sec Return Note Actual settings may vary tp6810 Figure 3 17 ATS Configuration Menu TP 6880 8 14 3 17 Date and Time Menu The date and time will typically be set at controller power up To change the date time or time format 12 hour or 24 hour use the Date and Time menu See Figure 3 18 3 18 Networking Information Menus Use the net
86. s above 16 Check the battery rating and VDC for more than 10 seconds Inhibited during condition the engine crank cycle Check the battery charger operation Clears when the battery voltage returns to an acceptable level Engine starting battery voltage falls below 12 5 Check the battery rating and VDC for more than 90 seconds when the engine condition is not running Not operative during the engine Check the battery charger operation crank cycle y l Clears when the battery voltage returns to an C narge LED ER tE Palely acceptable level Battery CrLo Warning Engine starting battery voltage falls below 11 Check the battery rating and Volts for more than 10 seconds Inhibited during condition the engine crank cycle Check the battery charger operation Clears when the battery voltage returns to an acceptable level Eng Speed SD Engine speed exceeds 115 of the normal Contact an authorized High running speed for more than 0 3 seconds distributor dealer for service Eng Speed Low SD Engine speed drops below 85 of the normal Reduce the load running speed for more than 3 seconds Contaci amauthorizdd distributor dealer for service Exer Not Sch Engine cooldown runs before shutting down Charge or replace the battery Exercise not scheduled No exercise is See Section 3 6 or 4 5 for instructions scheduled on the controller to set the exerciser E TP 6880 8 14 Section 2 Generator Set Operat
87. s backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe Injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid 10 Safety Precautions and Instructions Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6880 8
88. s noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts A DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and relate
89. save the setting and move on to the next Repeat until all settings are saved and the controller returns to the Main menu See Section 3 5 for more detailed instructions to change settings on the RDC2 See Section 3 6 for more detailed instructions to set the exerciser or change the exercise settings 3 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The RDC2 controller monitors the battery voltage and provides a constant 14 0 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz utility power provided from the building on a breaker protected circuit for the built in battery charger 3 5 Changing Settings Some settings can be changed from the controller keypad The controller settings and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the settings and or output when e he controller has been replaced e The voltage requires adjustment for a particular application e Troubleshooting generator set problems Have controller setup and adjustment performed only by an authorized Kohler distributor dealer or authorized representative 34 Section 3 RDC2 Controller Operation The following procedure explains how to change settings See Figure 3 7 for an example using the Date and Time settings Note Use caution when navigating the controller menu
90. side panel of the enclosure by removing the two screws 4 Disconnect the generator set engine starting battery negative lead first 5 Press the button on the thermostat to reset it See Figure 1 2 for the thermostat location 6 Reconnect the generator set engine starting battery negative lead last 7 Replace the air intake panel and service door 8 Reconnect utility power to the generator set by closing the circuit breaker in the distribution panel 9 Reset the fault on the RDC2 controller Refer to the generator Operation Manual for instructions if necessary Section 2 Generator Set Operation 29 Notes 30 Section 2 Generator Set Operation TP 6880 8 14 Section 3 RDC2 Controller Operation 3 1 RDC2 Generator Set Transfer Switch Controller Model RESV generator sets are eguipped with the RDC2 generator set transfer switch controller Model RESVL generator sets are eguipped with the DC2 controller See Section 4 for DC2 controller operation information The RDC2 controls the following power system components e Model 8RESV 10RESV or 12RESV generator set e Model RXT Automatic Transfer Switch ATS e Load Control Module LCM or load shed kit e Programmable Interface Module PIM The RDC2 controller features include e Two line x 16 character backlit digital display with adjustable contrast e OFF AUTO and RUN generator set master control buttons e Generator set status indicating LEDs OFF
91. supply and valves Engine malfunction Contact an authorized Kohler distributor dealer Gererator thermostat tripped For trips other than temperature nuisance trips reset the thermostat See Section 2 6 No AC output Line circuit breaker in the OFF position Place the circuit breaker in the ON position Line circuit breaker tripping because of Reduce the load on the generator set overload Line circuit breaker tripping because of short Contact an authorized Kohler distributor dealer for circuit service Auxiliary winding circuit breaker tripped Reset the circuit breaker located in junction box Contact an authorized a distributor dealer o service if breaker trips repeatedly Reduce the load Low output or Generator set overloaded excessive drop in voltage Generator set Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if stops suddenly necessary Out of fuel of fuel Check fuel Check fuel supply si gutte shutdown Creek Me suo z the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer Auxiliary winding circuit breaker tripped Reset the circuit breaker located in junction box Contact an authorized MR distributor dealer 2 service if breaker trips repeatedly Fault shutdown Check the controller display for fault messages See Section 2 5 Correct the fault condition and reset the controller Generator set in the OFF m
92. t Detection begins 10 seconds distributor dealer for service after crank disconnect Warning after 1 second if no output detected after crank disconnect Shutdown after 3 seconds if voltage was present and then lost Accy PwrOver Warning Accessory Power Overload An over current fault Contact an authorized short circuit on the accessory controller power distributor dealer for service output J Alt Protect High generator current has been detected The Reduce the load generator set shuts down to protect the alternator from damage caused by overheating the windings 10RESV and 12RESV only ATS communication error Warning is displayed Check communication wiring between if ATS interface connection is lost transfer switch interface board and See Section 2 5 3 generator set ATS phase rotation mismatch Transfer switch Correct the ATS connection Refer to phase rotation does not match ATS will not the ATS Installation manual wiring ATS ComError ATS PhaseRot transfer diagrams and labels on the transfer switch Aux Input Auxiliary input An optional customer connected Check customer supplied equipment input is closed Digital input from optional PIM Batt Chg Fit Battery charger fault Input to PIM from an Check external battery charger external battery charger not the built in battery charger Battery High Battery Low EEE ep U Engine starting battery voltage rise
93. t Genset Status Running Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure OK Battery 12 3V Engine Runtime 12345 6 h Date 02DEC2011 Time HR MNpm Sample data shown tp6804 Figure 3 5 Autopaging Displays Generator Running TP 6880 8 14 The display contrast is adjustable Navigate to the Genset System menu and step down to the Contrast screen Press the Select button and then use the up and down arrow buttons to adjust the contrast See Section 3 5 Changing Settings and Section 3 14 Genset System Menu The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Genset Status Standby Battery 12 3V Engine Runtime 12345 6 h Date 02DEC2011 Time HR MNpm Next Exercise 09 00p 09Dec2011 Next Maintenance 150 h or Mar2012 Sample data shown tp6804 Figure 3 6 Autopaging Displays Automatic Mode Section 3 RDC2 Controller Operation 33 3 3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built in battery charger Note To disconnect controller power disconnect the utility power to the generator set and disconnect the battery If controller power is disconnected and reconnected you willbe prompted to setthetime date and exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to
94. t weekly or every two weeks is required to keep the engine and alternator in good operating condition Three exercise modes are available unloaded cycle unloaded full speed and loaded full speed See Sections 2 4 2 through 2 4 4 for information about the exercise modes A loaded exercise can be set at the RDC2 controller only if a Model RXT transfer switch is connected Note With transfer switches other than the Model RXT it is possible to have two exercise settings one unloaded exercise set at the generator set controller and another exercise set at the ATS controller If the exercise times overlap the ATS exercise setting takes priority If a transfer switch other than the Model RXT is used refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS if desired 2 4 1 Setting the Exerciser When power is applied to the RDC2 controller that is when the battery is connected you will be prompted to set the date and time and then to set the exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next See Section 3 5 for 24 Section 2 Generator Set Operation more detailed instructions to change settings on the RDC2 See Section 3 6 for more detailed instructions to set the exerciser or change the exercise settings The DC2 controller does not prompt you to set the exerciser See Sectio
95. tailed information about the LCM operation refer to TT 1574 provided with the LCM kit For detailed information about the Load Shed kit operation refer to TT 1609 provided with the Load Shed kit Test Outputs Push Select blinking Input 1 In Active Input 2 In Active Output 1 Add Shed Output 2 Add Shed Output 3 Add Shed Output 4 Add Shed Output 5 Add Shed Output 6 Add Shed Return tp6810 Figure 3 25 Load Control Module LCM or Load Shed Kit Status Menu 52 Section 3 RDC2 Controller Operation TP 6880 8 14 3 21 Event Log The event log displays up to 1000 controller faults and notices starting with the most recent event Events are numbered 1 1000 with 1 being the most recent Each event is displayed with the date and time of the event the number ofthe 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 The time and date for notices I are not stored in the controller Procedure to View Event History 1 Press Select to enter the main menu 2 Pressthedown arrowtostepdowntotheeventlog 3 Press Select to display the most recent event 4 Press the down arrow to step to the next event 5 Usethe up and down arrow buttonsto view events Oo Press the Select button to exit the event log TP 6880 8 14 To stop viewing the event history before
96. tepper motor coupling and bushing T i LE 500 hours 7 i i i EEE ey a M a ai o Yeahyorso0hous Measure and record resistance readings of windings with insulation tester Megger with dare SCR assembly or rectifier and load leads disconnected General Condition of Equipment Condition of General Condition of Equipment Evidence of vibration leakage excessive noise Weekl temperature or deterioration y Interior of sound enclosure L S PM Quarterly Not necessary for maintenance free batteries X Action Service more frequently under extremely dusty dirty conditions D Authorized distributor dealer only Megger is a registered trademark of Biddle Instruments R Replace as necessary TP 6880 8 14 Section 5 Scheduled Maintenance 63 5 2 Lubrication System See the service schedules in Section 5 1 for oil change and oil filter replacement intervals See the service views in Section 1 9 for the oil drain oil check oil fill and oil filter locations 5 2 1 Low Oil Pressure Shutdown The low oil pressure LOP shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction Note The LOP shutdown feature does not protect against damage caused by operating when the oil level is low it is not a low oil level shutdown Check the oil level regularly and add oil as needed 5 2 2 Oil C
97. ter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator E2PROM EEPROM E emer ECM EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth in H20 in Hg in Ib Inc ind int int ext I O IP ISO J JIS k K kA KB KBus kg exhaust external Fahrenheit female flat head machine screw fluid ounce flexible frequency full scale foot feet foot pou
98. that are clear and easy to read even in direct sunlight or low light RDC2 Controller Features Six button keypad o OFF AUTO and RUN pushbuttons o Select and arrow buttons for access to system configuration and adjustment menus LED indicators for OFF AUTO and RUN modes LED indicators for utility power and generator set source availability and ATS position Model RXT transfer switch reguired LCD display o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility in all lighting conditions Scrolling system status display o Generator set status o Voltage and frequency o Engine temperature o Oil pressure o Battery voltage o Engine runtime hours Date and time displays Smart engine cooldown senses engine temperature Digital isochronous governor to maintain steady state speed at all loads Digital voltage regulation 0 596 RMS no load to full load Automatic start with programmed cranking cycle Programmable exerciser can be set to start automatically on any future day and time and run every week or every two weeks Exercise modes o Unloaded weekly exercise with complete system diagnostics o Unloaded full speed exercise o Loaded full speed exercise Model RXT ATS required 16 Section 1 Descriptions and Service Views Front access mini USB connector for SiteTech connection or the Kohler USB utility Integral Ethernet connector for Kohler OnCue
99. the procedure in Figure 3 8 and select Exercise Mode Unloaded Full 2 4 4 Loaded Full Speed Exercise with RXT only A loaded exercise starts the generator set ramps up to full speed and then transfers the electrical load from the utility source to the generator set After 20 minutes the load is transferred back to the utility source The engine runs without load for 5 minutes or until cool and then shuts down automatically Note With a loaded exercise power to the building is lost for up to 10 seconds during load transfer For a loaded exercise controlled by the RDC2 or DC2 controller a Model RXT transfer switch must be connected to the generator set To set a loaded exercise follow the procedure in Figure 3 8 and select Exercise Type Loaded Foraloaded exercise with a transfer switch other than a Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions 2 4 5 Power Failure During Exercise Cycle If the utility power is lost during an unloaded exercise the ATStransfersto the emergency source the exercise is ended and the control remains in the AUTO mode If the utility power is lost during a loaded exercise the exercise is ended The ATS remains in the emergency position and the control goes into the AUTO mode The generator set continues to run and supply power to the load for the duration of the utility power outage When Utilit
100. the rubber seal on the air cleaner stud and replace the seal if necessary Reinstall the paper element and the air cleaner cover Secure the cover with the cover retaining knobs Reconnect the utility power to the generator set Reconnect the generator set engine starting battery negative lead last Section 5 Scheduled Maintenance 67 5 4 2 Air Cleaner 10 12RESV RESVL Models The engine is equipped with a replaceable high density paper air cleaner element See Figure 5 7 ls fil Ze ZZ 7 Di 1 Air cleaner cover lever 2 Air cleaner element 3 Base 4 Blower housing 5 Air cleaner cover Figure 5 7 Air Cleaner Components Checkthe air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Paper Element Service Replace the paper element at the intervals indicated in the service schedule See Figure 5 7 for the air cleaner components 68 Section 5 Scheduled Maintenance 1 Press the OFF button on the generator set controller 2 Disconnect the utility power to the generator set 3 Disconnect the generator set engine starting battery negative lead first A
101. tworking gt Status OnCue Status Connected DHCP Enabled IP Address 123 456 789 123 Subnet Mask 123 456 789 123 Gateway 123 456 789 123 DNS 1 123 456 789 123 DNS 2 123 456 789 123 Ethernet Status Disconnected OnCue Server 123 456 789 123 Figure 3 20 Network Status Submenu 46 Section 3 RDC2 Controller Operation tp6804 TP 6880 8 14 3 18 2 Networking Configuration Submenu OnCue Plus Password The Networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System Password Note Use the OnCue password shown on the controller display for OnCue Plus applications For the initial OnCue Plus setup you will be required to resetthe OnCue password on the RDC2 controller and then enter it into the OnCue Plus software To resetthe password follow the instructions in Figure 3 21 Note The password is displayed for only 10 seconds Be sure to write down the password and serial number A new password is generated each time the reset password procedure is performed If the password is TP 6880 8 14 reset after the OnCue Plus system has been set up the connection will be lost Disconnect the battery power to the controller wait a minute then reconnect power DHCP Submenu For most applications the Dynamic Host Configuration Protocol DHCP is enabled and the IP settings cannot be changed from the controll
102. ule PIM this menu appears only if a PIM is connected This is a status display menu only Input and output settings cannot be changed from the RDC2 controller s user interface jn A personal computer running Kohler SiteTech software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohler OnCue Plus Management System can be used to turn outputs on and off See the OnCue Plus Software Operation Manual for instructions Input 1 In Active Input 2 In Active Output 1 In Active Output 2 In Active Output 3 In Active Output 4 In Active Output 5 In Active Output 6 In Active tp6810 Figure 3 24 Programmable Interface Module PIM Status Menu TP 6880 8 14 Section 3 RDC2 Controller Operation 51 3 20 Load Control Module LCM or Load Shed Kit Menus The Load Control menu displays the status of the Load Control Module LCM or load shed kit inputs and outputs and allows a test of the LCM or load shed kit output relays This menu appears only if an LCM or load shed kit is connected Generator current is displayed as a percent of the maximum generator capacity The load control module Load gt Generator Control Current 123 96 Load Control 1 or load shed kit adds and sheds loads based on the generator current The test function cycles the relays in the order of their priority For de
103. ure o Oil pressure o Battery voltage o Engine runtime hours o Maintenance reminders o OnCue Plus status connected disconnected e Date and time displays e Smart engine cooldown senses engine temperature e Digital isochronous governor to maintain steady state speed at all loads e Digital voltage regulation 0 5 RMS no load to full load e Automatic start with programmed cranking cycle e Exercise modes o Unloaded weekly exercise with complete system diagnostics o Unloaded full speed exercise TP 6880 8 14 o Loaded full speed exercise Model RXT ATS required e Front access mini USB connector for SiteTech connection or the Kohler USB utility e Integral Ethernet connector for Kohler OnCue Plus e Built in 2 5 amp battery charger e Remote two wire start stop capability for optional connection of Model RDT or RSB transfer switches e Diagnostic messages o Displays diagnostic messages for the engine generator set model RXT transfer switch and optional programmable interface module PIM and load control module LCM or load shed kit o Over 70 diagnostic messages can be displayed e A laptop computer and Kohler SiteTech software can be used to change system settings e Alaptop computer and Kohler SiteTech software or Kohler USB Utility software can be used to update controller firmware oee the generator set Installation manual for more information 1 7 OnCue Plus Generator Management System
104. ure 2 2 Clearing a Fault on the RDC2 Controller 26 Section 2 Generator Set Operation 2 5 4 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Check the fault message displayed on the controller and refer to Figure 2 3 to identify and correct the fault condition before proceeding Contact an authorized distributor dealer for service if necessary RDC2 Controller Pressthe OFF button to resetthe controller or follow the procedure below See Figure 2 2 1 While the fault message is displayed press the Select button to go to the Overview menu 2 Press Select again The active fault message is displayed 3 PressSelect Confirm Clear Fault NO is displayed 4 Pressthe Down arrow button Confirm Clear Fault YES is displayed 5 Press the Select button to enter YES and clear the fault 6 Press the Select button to return to the overview menu The controller changes to OFF mode 7 Press AUTO to putthe generator set into automatic mode DC2 Controller Press the OFF button to clear the fault message on the controller Fault Message 9 Confirm Clear 9 Fault NO Press Up arrow button Confirm Clear Fault YES TP 6880 8 14 Warning W or Fault Message Shutdown SD Condition Check W AC Sens Loss 1 sec AC sensing lost In Auto mode generator output Contact an authorized SD 3 sec AC sensing is los
105. ure 4 3 DC2 Controller Pushbutton Operation RUN LED is on Generator set is running Remote start and stop commands are ignored OFF OFF LED lights for 2 Generator set and controller are off Remote start stop commands have no seconds then flashes effect The exercise cycle will not run every 2 seconds In Auto mode OFF LED Attention required Identify and correct the fault condition before resetting the flashes quickly to indicate controller a fault shutdown AUTO LED is on Automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands or an ATS Time delays operate as described in Section 2 3 Figure 4 4 DC2 Controller LED Operation 56 Section 4 DC2 Controller Operation TP 6880 8 14 4 2 3 LCD Display The controller is eguipped with a two line x 16 character backlit digital display with adjustable contrast When the generator set is running the messages shown in Figure 4 5 are displayed When the system is in AUTO the LCD display steps through the status messages shown in Figure 4 6 When a fault or warning condition exists the controller will show the corresponding message See Section 2 5 for more information on fault and warning messages The display backlight turns off after about a minute of no activity The backlightturns on when a button is pressed or when the generator set starts Active Alert if any Running A
106. ury 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 eguipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square Inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble TP 6880 8 14 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardou
107. us information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings Status information including the engine runtime cannot be changed by the operator Diagrams in the following sections show how to navigate through the menus Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Status Overview Displays 1 2h Press the Up and Down arrow buttons to move between menus Press OFF or AUTO to exit the menus Engine gt Metering Generator gt Metering Genset gt Information Genset gt Run Time Ifa setting on the controller display is flashing edit mode has been enabled Pressthe OFF or AUTO buttonto exit the edit mode 3 8 Main Menu Press the Select button once to bring up the main menu Overview is displayed See Figure 3 9 Press the down arrow button to step to the next menu Engine Metering Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3 9 The controller will exit the main menu after 5 minutes if no buttons are pressed To exit the main menu immediately press the controllers OFF or AUTO button ATS Configuration Date gt and Time Netwo
108. working menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or LCM or load shed kit and for systems that use the Kohler OnCue Plus Generator Management System RBUS is a proprietary RS 485 communications protocol The Networking Information menu leads to submenus for network and RBUS communication settings Networking gt persone gt CC peers Networking gt Information N Networking gt Configuration RBUS eng Figure 3 19 Networking Information Menu TP 6880 8 14 Date and Time Date 02Dec2011 Time 12 34pm Time Format 12hr 24hr tp6804 To change the date and time press the Select button See Figure 3 7 for instructions Figure 3 18 Date and Time Menu Lc EL See Figure 3 20 me See Figure 3 21 O See Figure 3 22 tp6810 Section 3 RDC2 Controller Operation 45 3 18 1 Networking Status Submenu If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e ifa static IP address is used the The Networking Status submenu contains settings for IP parameters are displayed OnCue Plus See the OnCue Plus Software Operation Manual for information about the appropriate network To enable or disable DHCP and change the IP settings settings for OnCue Plus Changes to these settings are go to the Networking Configuration menu See not typically required Section 3 18 2 Networking gt Information Ne
109. y power is restored the ATS will re transfer to the utility source through normal timing sequences Section 2 Generator Set Operation 25 2 5 Faults The RDC2 DC2 controller displays fault messages for generator set warnings and shutdowns Selected fault messages are shown in Figure 2 3 2 5 1 Warnings The controller displays a fault message but the generator set does not shut down on a warning The controller resets automatically after a warning condition is corrected 2 5 2 Shutdowns Under a fault shutdown condition the generator set shuts down automatically and the controller displays a fault message The OFF LED flashes In some cases the engine cooldown cycle runs before the engine shuts down See Figure 2 3 Shutdown switches such as the low oil pressure switch or high engine temperature switch on the generator set will automatically reset when the problem is corrected However the fault condition at the controller does not clear until the controller is reset The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 5 4 for instructions to reset the controller after a fault shutdown 2 5 3 ATS Communication Errors When a Model RXT transfer switch is used an ATS fault indicates that the connection to the interface board on the transfer switch has been lost Check the connection to the ATS interface board Fault Message Overview 1 2h Fig

Owners Manual - - A & A Power Generators

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Owners Manual - - A &amp; A Power Generators

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Owners Manual - - A & A Power Generators