Related Manuals for Kohler 14/20RESA
Summary of Contents for Kohler 14/20RESA
- Page 1 Operation Residential/Commercial Generator Sets Models: 14/20RESA 14/20RESAL Controllers: RDC2 TP-6804 12/11...
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Page 2: Product Identification Information
California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ............Safety Precautions and Instructions . -
Page 4: Table Of Contents, Continued
Table of Contents, continued RDC2 Controller Menus ..........Main Menu . - Page 5 Table of Contents, continued Storage Procedure ........... . 5.8.1 Lubricating System .
- Page 6 Notes TP-6804 12/11...
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Page 7: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death. -
Page 8: Exhaust System
Battery gases. Explosion can cause Servicing the air cleaner. A sudden Generator set operation. Carbon severe injury or death. Battery gases backfire can cause severe injury or monoxide can cause severe nausea, can cause an explosion. Do not smoke death. Do not operate the generator fainting, or death. - Page 9 Fuel System Hazardous Noise WARNING CAUTION WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe Hazardous noise. injury, or death. Explosive fuel vapors. Can cause hearing loss. Can cause severe injury or death. If the generator set is used for Never operate the generator set standby power, install an automatic Use extreme care when handling,...
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Page 10: Hot Parts
Welding on the generator set. Can Hot Parts Notice cause severe electrical equipment damage. Before welding on the NOTICE WARNING generator set perform the following Canadian installations only. steps: (1) Remove the battery cables, standby service connect the output of negative (--) lead first. -
Page 11: Introduction
RDT Automatic Transfer Switch TP-6345 Information in this publication represents data available Installation Manual, Model RSB at the time of print. Kohler Co. reserves the right to Automatic Transfer Switch TP-6486 change this publication and the products represented Operation Manual, Model RSB... -
Page 12: Emission Information
The Kohlerr Model CH740 engine used on the 14RESA/RESAL generator set is certified to operate using natural gas or propane fuel. The Kohler Model CH1000 engine used on the 20RESA/RESAL generator set is certified to operate using propane fuel. The CH1000 engine used on the... -
Page 13: Service Assistance
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product. - Page 14 Notes Service Assistance TP-6804 12/11...
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Page 15: Section 1 Descriptions And Service Views
Kohlerr engine. The engine operates on clean- interface with and control the Kohler Model RXT burning natural gas or propane (LP) vapor. Engine Automatic Transfer Switch (ATS). Do not use the Kohler features include: Model RRT transfer switch with the RDC2 or DC2 Efficient overhead valve design and full pressure controller. - Page 16 The controller’s 2-line LCD screen displays status Front-access mini USB connector for SiteTecht messages and system settings that are clear and easy connection to read, even in direct sunlight or low light. Front access mini-breaker protects the alternator RDC2 Controller Features Integral Ethernet connector for Kohlerr OnCuet Six-button keypad Built-in 2.5 amp battery charger...
- Page 17 DC2 Controller Features Automatic start with programmed cranking cycle Four-button keypad: OFF, AUTO, RUN, and Exercise modes EXERCISE pushbuttons Unloaded weekly exercise with complete system LED indicators for OFF, AUTO, and RUN modes diagnostics Unloaded full-speed exercise LCD display: Loaded full-speed exercise (Model RXT ATS Two lines x 16 characters per line required) Backlit display with adjustable contrast for...
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Page 18: Accessories
1.7 Accessories 1.7.4 Programmable Interface Module (PIM) The following optional accessories are offered for the RESA and RESAL generator sets. The optional Programmable Interface Module (PIM) provides programmable inputs programmable dry contact outputs for connection to 1.7.1 Carburetor Heater customer-supplied equipment. The outputs are controlled by the RDC2 controller, and can also be An optional carburetor heater is recommended for... -
Page 19: Service Views
1.8 Service Views 16, 17 AIR INTAKE SIDE --PANEL REMOVED TO SHOW DETAIL ADV-8424 1. Hinged inner cover 15. RDC2 or DC2 controller 2. Hinged roof 16. Field-connection terminal block (behind panel) 3. Air intake 17. Digital spark advance ignition (DSAI) leads 4. - Page 20 Notes Section 1 Descriptions and Service Views TP-6804 12/11...
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Page 21: Section 2 Generator Set Operation
Section 2 Generator Set Operation 2.1 Prestart Checklist 2.3 Generator Set Operation To ensure continued satisfactory operation, perform the 2.3.1 Local Starting and Stopping following checks or inspections before or at each startup, as designated, and at the intervals specified in Start: Press the RUN button to immediately start the the service schedule. -
Page 22: Automatic Operation With Model Rxt Transfer Switch
2.3.6 Automatic Operation with Model RXT Transfer Switch If a Kohler Model RDT or RSB transfer switch is used, the engine start contacts from the ATS must be The Model RXT transfer switch connects to the RDC2 connected to engine start leads 3 and 4 on the generator controller through the ATS interface board on the set. -
Page 23: Exercise
2.4 Exercise Runs at reduced speed for 10 minutes to warm up and exercise the engine. The RDC2 and DC2 controllers can be set to Ramps up and runs at full speed for 3 minutes. automatically run the generator set at the same time and Engine diagnostics are performed during this day each week. -
Page 24: Unloaded Full-Speed Exercise
RDC2/DC2 controller to check the output power for The generator set continues to run and supply power to correct voltage, frequency, and stability. When the the load for the duration of the utility power outage. engine is running at full speed, the controller verifies When Utility power is restored, the ATS will re-transfer to that the voltage and frequency are within acceptable the utility source through normal timing sequences. -
Page 25: Resetting The Controller After A Fault Shutdown
2.5.4 Resetting the Controller after a 3. Press Select. Confirm Clear Fault: NO is displayed. Fault Shutdown 4. Press the Down arrow button. Confirm Clear Fault: Always identify and correct the cause of a fault YES is displayed. shutdown before resetting the controller. Check the fault message displayed on the controller and refer to 5. -
Page 26: Fault Messages
Warning (W) or Shutdown (SD) Condition Fault Message Check AC Sens Lost W (1 sec.) AC sensing lost. In Auto mode, generator output Contact an authorized AC sensing is lost. Starts 10 seconds after distributor/dealer for service. SD (3 sec.) * crank disconnect. - Page 27 Warning (W) or Shutdown (SD) Condition Fault Check Generator SD * Governed frequency exceeds 110% of the Contact an authorized Frequency High system’s frequency setpoint for more than 10 distributor/dealer for service. seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Generator SD * Governed frequency falls below 90% of the...
- Page 28 Notes Section 2 Generator Set Operation TP-6804 12/11...
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Page 29: Section 3 Rdc2 Controller Operation
Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/ Transfer Switch Controller Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller. Model RESAL generator sets are equipped with the DC2 controller. See Section 4 for DC2 controller operation information. -
Page 30: Controller Keypad
3.2.1 Controller Keypad 3.2.2 LED Indicators The RUN, OFF, and AUTO buttons control the generator LEDs above the RUN, OFF, and AUTO buttons indicate set as described in Figure 3-3. the mode of operation as shown in Figure 3-4. Use the Select, Up arrow, and Down arrow buttons to Power System LEDs indicate the status of the utility navigate through the menus and change settings, if power and the generator set, and indicate which source... -
Page 31: Lcd Display
3.2.3 LCD Display The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast The controller is equipped with a two-line x 16 character screen. Press the Select button, and then use the up backlit digital display with adjustable contrast. -
Page 32: Controller Power
Note: If no buttons are pushed, the controller exits the Have controller setup and adjustment performed only by menus and returns to the generator set status an authorized Kohler distributor/dealer or authorized display after 5 minutes. representative. Section 3 RDC2 Controller Operation... - Page 33 Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview ----> Press: Display: Date: 1.2 h Press: Display: 03Jan2012 2.
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Page 34: Setting The Exerciser
3.6 Setting the Exerciser 7. Press the Select button. The setting flashes to show that it can be changed. For example, HR Set the exerciser to automatically run the generator set flashes to show that the hour can be changed. for 20 minutes every week or every two weeks. - Page 35 Genset ----> System Freq: 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 HOLD: Exercise Mode: Exercise Mode: Unloaded Cycle/Unloaded Loaded Full/ Loaded Full HOLD: Exercise Freq: Exercise Freq: Weekly Weekly/Bi-Weekly Language:...
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Page 36: Rdc2 Controller Menus
3.7 RDC2 Controller Menus 3.8 Main Menu Controller menus display power system information, Press the Select button once to bring up the main menu. including status information for the engine, generator, Overview is displayed. See Figure 3-9. Press the down and optional RBUS accessories, exercise settings, and arrow button to step to the next menu, Engine Metering. -
Page 37: Overview Menu
3.9 Overview Menu 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 Overview ----> Active Alert changed from this menu. 1.2 h (if any) Eng Speed: Engine ---->... -
Page 38: Generator Metering Menu
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. -
Page 39: Generator Set Information Menu
Kohler SiteTech software is required to enter the manufacturer’s recommendation for changing the oil. generator set model number and serial numbers on a Refer to Section 5, Scheduled Maintenance, for replacement controller. Contact an authorized Kohler maintenance instructions. -
Page 40: Genset System Menu
Figure 3-15. Generator sets are System factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can adjust System Freq: these settings, if necessary. If the generator set is 60 Hz... -
Page 41: Ats Status Menu
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 The voltage shown in these menus can be calibrated. connected to the generator set. If no transfer switch is Follow the safety precautions at the beginning of this connected, or another model ATS is connected to the manuals. -
Page 42: Ats Configuration Menu
3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a ATS ----> Normal Freq: Model RXT transfer switch is connected. Configuration 12.3 Hz Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. -
Page 43: Date And Time Menu
3.17 Date and Time Menu Date and The date and time will typically be set at controller Date: Time power--up. To change the date, time, or time format 02Dec2011 (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18. -
Page 44: Networking Status Submenu
3.18.1 Networking Status Submenu If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the The Networking Status submenu contains settings for IP parameters are displayed. OnCuet. See the OnCue Software Operation Manual for information about the appropriate network settings To enable or disable DHCP and change the IP settings, for OnCue. -
Page 45: Networking Configuration Submenu (Oncue Password)
3.18.2 Networking Configuration Password Submenu (OnCue Password) For the initial OnCue setup, you will be required to reset the OnCue password on the RDC2 controller, and then The networking Configuration menu includes settings enter it into the OnCue software. To reset the password, used for communication with the Kohlerr OnCuet follow the instructions in Figure 3-21. -
Page 46: Rbus Information
3.18.3 RBUS Information Model RXT transfer switch The RBUS Information menu contains settings for Programmable Interface Module (PIM) remote modules that communicate with the RDC2 Load Control Module (LCM) controller using RBUS protocol. This includes the following optional modules: Networking----> Networking---->... -
Page 47: Remote Devices Submenu
3.18.4 Remote Devices Submenu The serial numbers for the PIM and LCM are printed on the circuit boards inside the enclosures. Check the status of remote devices communicating through RBUS. Device types can include: Model RXT ATS Programmable Interface Module (PIM) Load Control Module (LCM) From Figure 3-22: Remote ---->... -
Page 48: Programmable Interface Module (Pim) Status Menu
3.19 Programmable Interface A personal computer running Kohlerr SiteTecht software is required to change the input and output Module (PIM) Status Menu settings. Contact an authorized distributor or dealer for service. The PIM status menu displays the status of inputs and outputs connected to the programmable interface The Kohlerr OnCuet Home Management System can module (PIM). -
Page 49: Load Control Module (Lcm) Menus
3.20 Load Control Module (LCM) Generator current is displayed as a percent of the maximum generator capacity. The load control module Menus adds and sheds loads based on the generator current. The Load Control menu displays the status of the Load The test function cycles the relays in the order of their Control Module (LCM) inputs and outputs, and allows a priority. -
Page 50: Event Log
3.21 Event Log 6. Press the Select button to exit the event log. To stop viewing the event history before the last event, The event log displays up to 1000 controller faults and press the select button to return to the main menu. notices, starting with the most recent event. -
Page 51: Section 4 Dc2 Controller Operation
Section 4 DC2 Controller Operation 4.1 DC2 Generator Set/ Transfer Switch Controller Model RESAL generator sets are equipped with the DC2 generator set/transfer switch controller. Model RESA generator sets are equipped with the RDC2 generator set/transfer switch controller. Section 3 for RDC2 controller operation information. The DC2 controls the following power system components: Model 14RESAL or 20RESAL generator set... -
Page 52: Controller Keypad
4.2.1 Controller Keypad 4.2.2 LED Indicators The RUN, OFF, and AUTO buttons control the 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. -
Page 53: Lcd Display
4.2.3 LCD Display Active Alert The controller is equipped with a two-line x 16 character (if any) 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, Genset State the LCD display steps through the status messages Standby... -
Page 54: Exercise
4.5 Exercise 4.5.3 Exerciser Reset To reset the exerciser to run at a different day and/or The DC2 controller can be set to automatically run the time, follow the procedure in Section 4.5.2 to enter the generator set at the same time and day each week. new exerciser settings. -
Page 55: Maintenance Timer
4.7 Maintenance Timer 4.8 OnCue Password The maintenance timer keeps track of the time until the To set the OnCue password on the DC2 controller, next recommended maintenance according to the 1. Press the OFF button and verify that the generator maintenance schedule for the 14RESAL or 20RESAL set is not running. - Page 56 Notes Section 4 DC2 Controller Operation TP-6804 12/11...
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Page 57: Section 5 Scheduled Maintenance
Section 5 Scheduled Maintenance WARNING WARNING Hot engine and exhaust system. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Do not work on the generator set until Disconnect the battery cables before it cools. working on the generator set. -
Page 58: Service Schedule, 14Resa/Resal Models
5.1.1 Service Schedule, 14RESA/RESAL Models Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil... -
Page 59: Service Schedule, 20Resa/Resal Models
5.1.2 Service Schedule, 20RESA/RESAL Models Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before each use Change oil Yearly or 150 hours Replace filter... -
Page 60: Lubrication System
5.2 Lubrication System 5.2.3 Engine Oil Recommendation Use 5W-30 API (American Petroleum Institute) Service See the service schedules in Section 5.1 for oil change Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and oil filter replacement intervals. See the service and thickens less than other oils and leaves the engine views in Section 1.8 for the oil drain, oil check, oil fill, and intake valves and pistons cleaner. -
Page 61: Resetting The Maintenance Timer
5. Reset the maintenance timer on the controller. Figure 5-3 Oil Cooler Location 5.2.5 Resetting the Maintenance Timer 14/20RESA (RDC2): 1. In the Overview menu, step down to the Next Maintenance screen. 2. Press the Select button. 3. Press the Up arrow button so that Reset Maint Timer? Yes is displayed. -
Page 62: Spark Plugs
4. Reinstall the spark plug into the cylinder head. Torque spark plug 24.4--29.8 Nm (18--22 ft. lb.) Generator Set Model Spark Plug Gap 14/20RESA/RESAL 0.76 mm (0.030 in.) Figure 5-4 Spark Plug Gap 586536 1. Cover knob 2. Air cleaner cover 3. Element cover nut 1--514 4. -
Page 63: Air Cleaner, 20Resa/Resal Models
Precleaner Service 7. Replace the element if it is dirty, bent, or damaged. Use the following procedure to wash and oil the 8. Check the air cleaner base. Make sure it is secure precleaner as indicated in the service schedule. Wash and not bent or damaged. -
Page 64: Cooling System
Make sure the element is flat and properly seated. Check that the exhaust outlet is clear. 6. Install the air cleaner cover and secure with the two retaining knobs. 7. When element replacement is necessary, order genuine Kohler parts. Section 5 Scheduled Maintenance TP-6804 12/11... -
Page 65: Battery
5.7 Battery 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 WARNING servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. -
Page 66: Storage Procedure
5.8 Storage Procedure 5.8.3 Cylinder Lubrication 1. Remove the spark plugs. Perform the following storage procedure before removing the generator set from service for three 2. Pour one tablespoon of engine oil into each spark months or longer. Follow the engine manufacturer’s plug hole. -
Page 67: Section 6 Troubleshooting
Some controller settings can be adjusted using a laptop recommended checks are listed in Figure 2-3. computer with Kohler SiteTech software. Use a USB cable with a mini-B connector to connect the controller to Identify and correct the cause of the fault condition. -
Page 68: Troubleshooting
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 controller’s service access area). -
Page 69: Appendix A Abbreviations
(2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6804 12/11 Appendix 69... - Page 70 kg/cm kilograms per square normally closed remote terminal unit centimeter National Electrical Code room temperature vulcanization kilogram-meter NEMA National Electrical read/write kg/m kilograms per cubic meter Manufacturers Association Society of Automotive kilohertz NFPA National Fire Protection Engineers Association kilojoule scfm standard cubic feet per minute newton meter kilometer...
- Page 72 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6804 12/11 7 Jurong Pier Road Singapore 619159 E 2011 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...