Kohler 14RCAL Installation Manual
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Kohler 14RCAL Installation Manual

Residential/commercial generator set
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Residential/Commercial Generator Set
Installation
Models:
14RCA
14RCAL
18RCAL
20RCA
20RCAL
Controller:
RDC2
TP-7091 11/22c

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Summary of Contents for Kohler 14RCAL

  • Page 1 Installation Residential/Commercial Generator Set Models: 14RCA 14RCAL 18RCAL 20RCA 20RCAL Controller: RDC2 TP-7091 11/22c...
  • Page 2 State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory- authorized dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................11 Service Assistance................................... 13 Section 1. Location and Mounting.......................... 15 Introduction ................................15 Lifting..................................16 Generator Set Inspection ............................17 Location and Mounting ............................17 1.4.1 Mounting Area............................17 1.4.2 Exhaust Requirements ..........................
  • Page 4 Cold Weather Package ..............................55 5.7.1 Battery Heater ............................55 5.7.2 Breather Tube and Oil Heater ........................56 5.7.3 Alternator Weather Cover ........................57 5.7.4 Oil Pressure Sensor Boot......................... 58 Section 6. Drawings and Diagrams ........................59 Appendix A. Abbreviations ............................73 TP-7091 11/22...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 6 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.
  • Page 7 Engine Backfire/Flash Fire WARNING Risk of fire. 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.
  • Page 8 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.
  • Page 9 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage.
  • Page 10 Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death.

  • Page 11: Introduction

    Do not install or operate this generator set indoors. 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.
  • Page 12 List of Related Literature Figure 2 identifies literature available for the generator sets and related accessories covered in this manual. Only trained and qualified personnel should install or service the generator set. Generator Set Literature Literature Part No. Specification Sheet, 14RCA/L G4-270 Specification Sheet, 18RCAL G4-313...

  • Page 13: Service Assistance

    • Visit the Kohler Co. website at KOHLERPower.com. • Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. • Call toll free in the US and Canada 1-800-544-2444.
  • Page 14 TP-7091 11/22...

  • Page 15: Location And Mounting

    Have the generator set installed by an authorized Kohler dealer or authorized representative. For all locations, ensure that the installation complies with applicable national and local codes. In the United States, the installation must comply with the N ational Electrical Code (NEC) and local codes.

  • Page 16: Lifting

    Lifting WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Generator set weights are shown in Figure 3. These shipping weights include the generator set and packaging with skid, but do not include the battery or an automatic transfer switch.

  • Page 17: Generator Set Inspection

    Generator Set Inspection Complete a thorough inspection of the generator set. Check for the following: Inspect the generator set for loose or damaged parts or wires. Repair or tighten any loose parts before installation. Check the engine oil. Fill, if necessary, with the recommended viscosity and grade of oil. Use synthetic oil, API (American Petroleum Institute) Service Class SG or higher.

  • Page 18: Exhaust Requirements

    1.4.2 Exhaust Requirements Figure 5 gives the exhaust temperature at rated load. The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure. Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the clearances shown in the dimension drawing.

  • Page 19: Access The Air Intake Area

    Access the Air Intake Area The battery, fuel system, and some electrical connections are located in the air intake area. Remove the enclosure p anel to access the air intake area during installation as described below. No tools are required to remove and replace the service -side, air intake end, or exhaust end panels.
  • Page 20 TP-7091 11/22...

  • Page 21: Section 2. Fuel

    Section 2. Fuel Fuel Requirements The generator set operates using natural gas or LPG fuel. The generator set is EPA-certified for both natural gas and LPG fuels. The fuel system installation must comply with applicable national, state, and local codes. WARNING Explosive fuel vapors.

  • Page 22: Fuel Pipe Size

    Fuel Consumption, m /hr. (cfh) 14RCA/RCAL 18RCAL 20RCA/RCAL Fuel Type % Load 60 Hz 60 Hz 60 Hz 100% 5.4 (193) 7.6 (268) 8.0 (281) 4.7 (163) 6.2 (219) 6.9 (243) Natural 3.5 (124) 4.4 (155) 4.6 (161) 2.6 (93) 3.5 (123) 3.6 (127) 100%...

  • Page 23: Connecting The Fuel Supply

    2.1.3 Connecting the Fuel Supply The dimension drawing in the Drawings and Diagrams section shows the location of the fuel inlet connection. Have the fuel supplier install rigid gas piping and a manual fuel shut-off valve. The fuel supply line should line up with the generator set fuel inlet and end about 12 inches away to allow connection with a section of flexible fuel line.

  • Page 24: Fuel Conversion

    After converting the fuel system, change the Fuel Type setting on the controller. See the Operation Manual for instructions t o © change settings at the controller, or use a personal (laptop) computer and Kohler SiteTech™ software to change the setting.

  • Page 25: Fuel Conversion, Original Fuel System, 14Rca/Rcal

    2.2.1 Fuel Conversion, Original Fuel System, 14RCA/RCAL For natural gas and LPG fuel, orifice fittings are used in the fuel line. See Figure 12. The natural gas orifice fitting is silver in color and stamped NG. The LPG fitting is gold in color and stamped LPG. The fittings are threaded. A straight-blade screwdriver is required to remove and replace the fittings.
  • Page 26 To convert from LPG to natural gas, repeat the steps above, removing the LPG fuel orifice and installing the NG fitting. Connect ignition timing leads 65 and N3 together for natural gas. Fuel orifice fitting Hose fitting GM102846 Figure 14 Fuel System Showing Orifice Fitting (14RCA/14RCAL) TP-7091 11/22...

  • Page 27: Fuel Conversion, Original Fuel System, 20Rca/Rcal

    2.2.2 Fuel Conversion, Original Fuel System, 20RCA/RCAL For LPG fuel, an orifice is used in the fuel line. The unit is typically shipped set up for natural gas, with the loose orifice tied near the fuel solenoid valve. To convert to LPG, install the LPG orifice as described below. See Figure 15 for the fuel system component locations.

  • Page 28: Fuel Conversion, Revised Fuel System, 14/18/20Rca/Rcal

    2.2.3 Fuel Conversion, Revised Fuel System, 14/18/20RCA/RCAL The revised fuel system uses a knob that controls a valve on the regulator to select the fuel type. See Figure 16 and Figure 17. Fuel selector Fuel inlet Integral fuel solenoid valve GM114166 Figure 16 Revised Fuel System...
  • Page 29 Fuel Selection, Revised Fuel System Press the OFF button on the generator set controller. Disconnect utility power to the generator set (open the corresponding circuit breaker in the distribution panel). Disconnect the generator set engine starting battery, negative (- ) lead first. Turn off the fuel supply.
  • Page 30 On 14 kW models, find the ignition timing leads 65 and N, located near the regulator. See Figure 20. For natural gas (NG), connect lead 65 to lead N3. For LPG, disconnect lead 65 from lead N3. Ignition timing leads Figure 20 Ignition Timing Leads (14 kW models only) Connect and turn on the fuel supply (Ensure that the fuel supply matches the fuel setting).

  • Page 31: Electrical

    Section 3. Electrical Electrical Connections DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present.

  • Page 32: Grounding

    3.1.2 Grounding Ground the generator set. The grounding method must comply with NEC and local codes. Connect the ground to the generator set ground lug, terminal GND in the customer connection area. See Figure 22. The requirement for having a bonded (grounded) neutral or ungrounded neutral is determined by the type of installation. The generator is shipped with a floating Neutral.

  • Page 33: Electrical Lead Entry

    3.1.3 Electrical Lead Entry Drill or punch holes in the enclosure for the electrical conduit in the locations shown in Figure 23. To avoid interference with the roof when it is open, use a 90-degree elbow at the AC voltage entry point and direct the conduit away from the roof. DO NOT DRILL HOLES IN THESE AREAS ADV- 9746...

  • Page 34: Field Connections

    3.1.4 Field Connections Customer connection points are located as shown in Figure 24. Open the enclosure roof and locate the cover panel over the circuit breaker. Remove the cover panel to access the power and load connections. Remove the air intake end panel for access to the engine start and communication connections to the transfer switch. See the ATS and Accessory Communication Connections section for more details about the transfer switch connections.
  • Page 35 4 (See detail) LOW VOLTAGE CONNECTION DETAIL GM101741C GM101739 Cover panel. Remove for access to power and load connections. Cover panel screws, qty. 2. Load circuit breaker. Transfer switch and accessory low voltage connections. Use cable tie to secure low voltage connections. Ground connection for communication cable shield.

  • Page 36: Ac Power Supply

    3.1.5 AC Power Supply The installer must connect AC power for the battery charger (which is integral to the RDC2 controller) and the optional accessories shown in Figure 25. The power source must comply with state and local codes. The power to the battery charger and accessories must be backed up by the generator so that power is available at all times.

  • Page 37: Battery

    Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.
  • Page 38 Battery Description Starting batteries are usually the lead-acid type. Use a 12-volt group 51 battery with a minimum rating of 500 cold cranking amps at 0°F. The generator set uses a negative ground with a 12-volt engine electrical system. See Figure 26 for battery connections. Make sure that the battery is correctly connected and the terminals are tight.

  • Page 39: Ats And Accessory Communication Connections

    ATS and Accessory Communication Connections The following sections cover communication connections from the generator set to automatic transfer switches and RBUS accessories, including the programmable interface module (PIM) and the load shed kit. 3.3.1 Communication Cable Specifications RBUS Connections A and B For the RBUS communication connections A and B to the optional RBUS modules, use 20 AWG shielded, twisted -pair communication cable.

  • Page 40: Transfer Switch Connection

    3.3.2 Transfer Switch Connection Connect the ATS or remote start/stop switch. Connect the load leads from the generator set to the Emergency source lugs on the ATS. Route low-voltage communication leads through separate conduit from the AC power and load leads. All connections must comply with applicable state and local codes.

  • Page 41: System Connections With Accessory Modules

    Generator Set (with engine start contacts) tp6803 Generator Set Terminal Block. Check the decal on the generator set for terminal block connections. Engine start leads 3 and 4. See the ATS manual for cable size specifications. Figure 29 Engine Start Connections with Transfer Switch Models other than Model RXT 3.3.3 System Connections with Accessory Modules See Figure 30 through Figure 34 for connection options to RBUS accessory modules.
  • Page 42 Generator Set 12 VDC Load Shed Kit RBUS Note: Connect A to A, B to B, PWR to PWR, and COM to COM. See the Communication Cable Specifications section.  RXT transfer switch with standard or combined interface/ load management board. Do not use a load shed kit with RXT* a combined interface board.
  • Page 43 Generator Set 12 VDC RBUS Load Shed Kit B PWR COM Note: See the Communication Cable Specifications section for maximum total cable lengths.  RXT* RXT transfer switch with standard or combined interface/ load management board. Do not use a load shed kit with a combined interface board.
  • Page 44 Generator Set RXT ATS Terminal Block Load Shed Kit Notes: • Check the decal on the generator set for terminal block connections. • 3 runs with 1 module each shown. • See Figure 30 for communication connection detail (A and B, PWR and COM).

  • Page 45: Prestart

    Section 4. Prestart Prestart Installation Check DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected.

  • Page 46: Set The Exerciser

    4.2.2 Loaded Exercise ® In order to set a loaded exercise using the RDC2 controller, a Kohler Model RXT transfer switch must be connected. See the generator set operation manual for instructions to set a loaded exercise. To set a loaded exercise on a generator set connected to a transfer switch other than a Model RXT, use the transfer switch controller to set the exercise.

  • Page 47: Accessories

    Section 5. Accessories Introduction This section describes some of the accessories that are available for the generator sets. Have accessories installed by an authorized dealer or a licensed electrician. This document does not contain installation instructions for accessories. Follow the installation instructions provided with each kit.
  • Page 48 Heater Thermostat Power plug GM19463 Carburetor Heater for 14 kW Models Power plug Thermostat Heater Carburetor Heater for 18 and 20 kW Models GM57968 240 Volt Plug Figure 37 Carburetor Heaters Carburetor heater power cord Carburetor heater (air cleaner removed to show heater) tp6195 Figure 38...
  • Page 49 adv-8954 tt1482b Carburetor heater location under air cleaner. Insert Carburetor heater from the back of the generator set. Figure 39 Carburetor Heater Location on 18 and 20 kW Models 120 VAC receptacle location Knockouts for 240 VAC plugs Figure 40 Power Connections for Carburetor Heaters TP-7091 11/22...

  • Page 50: Programmable Interface Module (Pim)

    Plus program. If an output is activated or deactivated through OnCue Plus, it is no longer controlled by the RDC2 controller. Kohler SiteTech software can be used to set the outputs back to generator-controlled events, if necessary. See the OnCue Plus manuals for instructions.

  • Page 51: Oncue Plus Generator Management System

    OnCue Plus Generator Management System ® The OnCue Plus Generator Management System allows monitoring and control of your generator set from a personal computer, smart phone, or tablet. OnCue Plus can also be configured to send email or text message notifications in the event of a generator set fault.

  • Page 52: Load Management Devices

    • Up to four normally closed power relays can be connected through normally open relay contacts on the circuit board. ® See the load shed kit installation instructions for relay specifications. Kohler Power Relay Modules are recommended. • Two relays are included on the load management device to control two independent heating, ventilation, and air conditioning (HVAC) loads.

  • Page 53: Power Relay Module

    5.5.1 Power Relay Module The power relay module kit contains one 50 amp normally closed relay with connecting lugs in a NEMA type 3R enclosure. Connect up to four (4) power relay modules to the load management devices listed above. The power relay modules can be mounted indoors or outdoors.
  • Page 54 Two single-phase generator sets as described above. APM RDC2.4 paralleling firmware for the blue-board controller on each generator set. Download the latest version of paralleling firmware from the Service Support section of the Kohler Power Resource Center (KPRC). One Model RXT automatic transfer switch (ATS).

  • Page 55: Cold Weather Package

    Cold Weather Package The cold weather package is recommended for reliable operation at temperatures below 0°C (32°F). The cold weather package includes the kits shown in the following sections. The kits shown below are also available separately. WARNING Hot engine and exhaust system. Can cause severe injury or death.

  • Page 56: Breather Tube And Oil Heater

    5.7.2 Breather Tube and Oil Heater The breather tube heater and oil heater kit is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). Note: The heaters require a continuous source of AC power. See Figure 49 and Figure 50 for the power supply voltage required. Note: The breather tube heater and oil heater must be used together.

  • Page 57: Alternator Weather Cover

    Note: For Models 14RCA(L): If the generator set is equipped with a carburetor heater, obtain kit GM102228-S to replace the breather tube, air cleaner spacer, and gaskets before installing the breather tube and oil heaters. If the generator set is equipped with a carburetor heater, remove it before installing the breather tube and oil heaters. The breather tube heating element wraps around the breather tube from the engine to the air cleaner.

  • Page 58: Oil Pressure Sensor Boot

    5.7.4 Oil Pressure Sensor Boot The oil pressure sensor boot protects the oil pressure sensor and its connection from moisture and frost buildup that can cause false low oil level faults. Install the oil pressure sensor boot in locations where the ambient temperature drops below 0°C (32°F). See Figure 55 for illustrations of the installed kit.

  • Page 59: Drawings And Diagrams

    Section 6. Drawings and Diagrams Figure 56 lists the drawing numbers and page numbers. Dimension Drawings Drawing Number Page Dimension Drawing: ADV-9746 Dimensions Sheet 1 Maintenance item locations Sheet 2 Maintenance item locations Sheet 3 Location and clearance requirements, single unit Sheet 4 Location and clearance requirements, parallel units Sheet 5...
  • Page 60 Figure 57 Dimension Drawing ADV-9746, Sheet 1 TP-7091 11/22...
  • Page 61 Figure 58 Dimension Drawing ADV-9746, Sheet 2 TP-7091 11/22...
  • Page 62 Figure 59 Dimension Drawing ADV-9746, Sheet 3 TP-7091 11/22...
  • Page 63 Figure 60 Dimension Drawing ADV-9746, Sheet 4 TP-7091 11/22...
  • Page 64 Figure 61 Dimension Drawing ADV-9746, Sheet 5 TP-7091 11/22...
  • Page 65 Figure 62 Schematic Diagram, ADV-9236, Sheet 1 TP-7091 11/22...
  • Page 66 Figure 63 Schematic Diagram, ADV-9236, Sheet 2 TP-7091 11/22...
  • Page 67 Figure 64 Schematic Diagram, ADV-9236, Sheet 3 TP-7091 11/22...
  • Page 68 Figure 65 Schematic Diagram, ADV-9236, Sheet 4 TP-7091 11/22...
  • Page 69 Figure 66 Wiring Diagram GM115458 Sheet 1, Single Phase, 2-Pole Circuit Breaker TP-7091 11/22...
  • Page 70 Figure 67 Wiring Diagram GM115458 Sheet 2, Single Phase, 2-Pole Circuit Breaker TP-7091 11/22...
  • Page 71 Figure 68 Wiring Diagram GM115458 Sheet 3, Three Phase, 3-Pole Circuit Breaker TP-7091 11/22...
  • Page 72 TP-7091 11/22...

  • Page 73: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control;...
  • Page 74 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 75 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 76 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. 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 watt...
  • Page 77 TP-7091 11/22...
  • Page 78 TP-7091 11/22...
  • Page 80 TP-7091 11/22c KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2018 Kohler Co. All rights reserved.

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