Kohler 14RCA Manual
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Kohler 14RCA Manual

Residential/commercial generator sets, controller
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Residential/Commercial Generator Sets
Operation
Models:
14RCA
14RCAL
20RCA
20RCAL
Controller:
RDC2
TP-7092 8/18

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Summary of Contents for Kohler 14RCA

  • Page 1 Operation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL Controller: RDC2 TP-7092 8/18...

  • Page 2: Product Identification Information

    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 distributors or dealers install and service the generator. Product Identification Information Controller Identification Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............. Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Setting the Exerciser ........... 3.6.1 Setting the Exerciser at Controller Power-up .
  • Page 5 Table of Contents, continued Section 5 Troubleshooting ..............Introduction .
  • Page 6 Notes TP-7092 8/18...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. 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, maintained. To prevent accidents be Explosion. Can cause severe injury or death. aware of potential dangers and act safely.

  • Page 8: Tp-7092

    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,...
  • Page 10 Hot Parts Notice Welding on the generator set. Can 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

    G4-273 Information in this publication represents data available Installation Manual, Generator Set TP-7091 at the time of print. Kohler Co. reserves the right to Service Manual, Generator Set TP-7093 change this publication and the products represented without notice and without any obligation or liability Transfer Switch Literature whatsoever.
  • Page 12 See the service views in Section 1.8 for the nameplate location. Refer to the certification label for engine displacement. The exhaust emission control system for the CH740 engines (14RCA/RCAL) is EM for U.S. EPA, California, and Europe. Genset Model The exhaust emission control system for the CH1000 Spec Number engine (20RCA/RCAL) is EM for U.S.

  • Page 13: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.
  • Page 14 Notes Service Assistance TP-7092 8/18...

  • Page 15: Section 1 Descriptions And Service Views

    1.5 Transfer Switch dealer. The RDC2 controller is designed to interface with and control the Kohler Model RXT Automatic Transfer 1.2 Engine Switch (ATS). The generator set has a four-cycle, twin cylinder, air- If the power system uses a different model transfer cooled Kohlerr engine.
  • Page 16 RDC2 Controller Features Front-access mini USB connector for Kohlerr SiteTecht connection Six-button keypad Integral Ethernet connector for the Kohlerr OnCuer OFF, AUTO, and RUN pushbuttons Plus Generator Management System Select and arrow buttons for access to system Built-in battery charger configuration and adjustment menus LED indicators for OFF, AUTO, and RUN modes Remote two-wire start/stop capability for connection...

  • Page 17: Accessories

    1.7.5 Concrete Mounting Pads OnCuer Plus can be configured to send email or text Kohler offers optional concrete mounting pads that are message notifications in the event of a generator set custom-designed Model 14RCA/RCAL fault. 20RCA/RCAL generator sets. Three-inch and four-inch thick pads are available.

  • Page 18: Service Views

    7. Lifting holes 23. Nameplate location 8. Fuel inlet 24. Field-connection terminal block (behind panel) 9. Air intake 25. Digital spark advance ignition (DSAI) lead location (14RCA/L 10. Low voltage electrical in only) 11. Oil check (dipstick) 26. Thermostat location 12.

  • Page 19: 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 DANGER 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.

  • Page 20: Local Starting And Stopping

    If a transfer switch other than the Model RXT (such as a run after the loads have been removed. Kohler Model RDT) is used, the engine start contacts The engine cooldown time delay is set to 5 minutes. The from the ATS must be connected to engine start leads 3 engine stops before the cooldown time delay expires if and 4 on the generator set.

  • Page 21: Exercise

    2.4.2 Unloaded Cycle Exercise with Press the AUTO button to put the controller into automatic mode. Complete System Diagnostics An unloaded exercise runs the generator set without Automatic Start signalling the transfer switch to transfer the electrical The engine start contacts on the ATS close to signal the load from the utility source to the generator set.

  • Page 22: Unloaded Full-Speed Exercise

    2.4.4 Loaded Full-Speed Exercise (with Battery voltage. Battery voltage is checked before exercise to verify engine starting capability. Battery RXT only) voltage provides a measurement of battery health. If the controller detects low battery voltage, the A loaded exercise starts the generator set, ramps up to condition is indicated on the display.

  • Page 23: Faults

    2.5 Faults 2.5.4 Resetting the Controller after a Fault Shutdown The RDC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault Always identify and correct the cause of a fault messages are shown in Figure 2-3. Contact an shutdown before resetting the controller.
  • Page 24 Warning (W) or Shutdown (SD) Condition Fault Message Check AC Sens Loss W (1 sec.) AC sensing lost. In Auto mode, generator output Contact an authorized AC sensing is lost. Detection begins10 seconds distributor/dealer for service. SD (3 sec.) * after crank disconnect.
  • Page 25 Warning (W) or Shutdown (SD) Condition Fault Check Frequency Low SD * 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 Model 20RCA/20RCAL only: Check setting for more than 60 seconds.

  • Page 26: Faults Related To Paralleling

    2.5.5 Faults Related to Paralleling See the installation instructions provided with the APM for additional paralleling information. If the PowerSyncr Automatic Paralleling Module (APM) is used with two 14 kw or two 20 kW generator sets, Note: Contact an authorized distributor or dealer for additional faults and events related to the paralleling paralleling system...
  • Page 27 Fault Text Description Possible Causes * ErraticSig The power metering on this controller gives a signal Bad wiring to the CT. that is not consistent with the system configuration. Too much tension on wires from the CT to Reversing the power direction does not resolve the the controller.
  • Page 28 Notes Section 2 Generator Set Operation TP-7092 8/18...

  • Page 29: Section 3 Rdc2 Controller Operation

    Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller Model RCA and RCAL generator sets are equipped with the RDC2 generator set/transfer switch controller. See Figure 3-1 for controller illustrations. The RDC2 controls the following power system components: Model RCA or RCAL generator set Model RXT Automatic Transfer Switch (ATS) Load management device...

  • 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

    3.3 Controller Power The following procedure explains how to change settings. See Figure 3-7 for an example using the Date The RDC2 controller is powered by the generator set and Time settings. engine starting battery and the built-in battery charger. Note: Use caution when navigating the controller Note: To disconnect controller power, disconnect the menus.
  • 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.

  • 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 System Battery Fuel Type 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...

  • Page 36: Rdc2 Controller Menus

    3.7 RDC2 Controller Menus If a setting on the controller display is flashing, edit mode has been enabled. Press the OFF or AUTO button to Controller menus display power system information, exit the edit mode. including status information for the engine, generator, and optional RBUS accessories, exercise settings, and 3.8 Main Menu event history.
  • Page 37 Status Overview ----> Displays 1.2 h Press the Up and Down arrow buttons Engine ----> ----> to move between menus. Metering Configuration * Press OFF or AUTO to exit the menus. Generator----> Date ----> Metering and Time Network ----> Genset ---->...

  • Page 38: 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 39: Generator Metering Menu

    The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized distributor/dealerdealer 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 40: Generator Set Information Menu

    A personal computer The Next Maintenance menu shows the number of running Kohler SiteTech software is required to enter the hours of generator set operation until maintenance is generator set model number and serial numbers on a required.

  • Page 41: Genset System Menu

    ----> System Voltage: 240 V System 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 System Freq: 3.5 for instructions to enable editing and change the...

  • Page 42: 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 43: 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 60 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 44: Date And Time Menu

    Use the networking menus to view and adjust Time Format: communication settings for systems with remote RBUS devices such as a PIM or load shed kit, and for systems 12hr|24hr that use the Kohler OnCuer Plus Generator Management System. <---- Return RBUS is a proprietary RS-485 communications protocol.

  • Page 45: Networking Status Submenu

    3.18.1 Networking Status Submenu To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. The Networking Status submenu contains settings for Section 3.18.2. OnCuer. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed.

  • Page 46: Networking Configuration Submenu (Oncue Password)

    Disconnect the battery power to Submenu (OnCue Password) the controller, wait a minute, then reconnect power. The Networking Configuration menu includes settings used for communication with the Kohler OnCuer Plus DHCP Submenu Generator Management System. For most applications, the Dynamic Host Configuration...
  • Page 47 Networking----> Networking----> Status Information HOLD Networking Reset OnCue Reset OnCue Configuration Password? No Password UP arrow for YES, Down arrow for NO. RBUS ----> Reset OnCue Information Password? Yes Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds.

  • Page 48: Rbus Information

    3.18.3 RBUS Information Model RXT transfer switch The RBUS Information menu contains settings for Combined interface/load managment board on the remote modules that communicate with the RDC2 RXT transfer switch controller using RBUS protocol. This includes the Programmable Interface Module (PIM) following optional modules: Load shed kit PowerSyncr Automatic Paralleling Module (APM)

  • Page 49: Remote Devices Submenu

    3.18.4 Remote Devices Submenu The serial number for the RBUS module is shown on the circuit board inside the module enclosure. Check the status of remote devices communicating through RBUS. Device types can include: Model RXT ATS Programmable Interface Module (PIM) Load shed combined...

  • Page 50: Programmable Interface Module (Pim) Status Menu

    3.19 Programmable Interface A personal computer running Kohler 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...

  • Page 51: Load Control Menus

    3.20 Load Control Menus Generator current is displayed as a percent of the maximum generator capacity. The load control module The Load Control menu displays the status of the load adds and sheds loads based on the generator current. management device inputs and outputs, and allows a The test function cycles the relays in the order of their test of the load control output relays.

  • Page 52: Event Log

    3.21 Event Log Date MO/DA/YEAR The event log displays up to 1000 controller faults and Event Log ----> time HR:MN notices, starting with the most recent event. Events are event number, W/S/I, engine hours numbered 1--1000, with 1 being the most recent. Each event name event is displayed with the date and time of the event, the number of the event, a code to indicate whether the...

  • Page 53: Section 4 Scheduled Maintenance

    Section 4 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 generator set.

  • Page 54: Service Schedule, 14 Kw Models

    4.1.1 Service Schedule, 14 kW 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 Every 8 hours of engine operation Crankcase breather hose Yearly or 500 hours...

  • Page 55: Service Schedule, 20 Kw Models

    4.1.2 Service Schedule, 20 kW 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 Every 8 hours of engine operation Change oil Yearly or 150 hours...

  • Page 56: Lubrication System

    4.2 Lubrication System 4.2.2 Oil Check The generator set is shipped with oil. Before operating See the service schedules in Section 4.1 for oil change the generator set, check the engine oil in the crankcase. and oil filter replacement intervals. See the service views in Section 1.8 for the oil drain, oil check, oil fill, and To check the oil level, shut down the generator set and oil filter locations.

  • Page 57: Oil Change Procedure

    4.2.4 Oil Change Procedure 3. Fill with oil. Note: Dispose of all waste materials (engine oil, fuel, Note: When the oil is drained, some oil remains in the filter, etc.) in an environmentally safe manner. engine. The amount of oil needed to refill the engine may be less than the capacity shown in Drain the oil while it is still warm.

  • Page 58: Resetting The Maintenance Timer

    4.2.6 Oil Cooler (20RCA/RCAL only) d. Reconnect the generator set engine starting battery, negative (--) lead last. Inspect and clean the oil cooler at the intervals indicated e. Reconnect the utility power to the generator in the service schedule. The oil cooler must be kept free set.

  • Page 59: Spark Plugs

    4.3 Spark Plugs 3. Check the spark plug gap using a wire feeler gauge. See Figure 4-5 for the recommended spark plug gap. Adjust the gap by carefully bending WARNING the ground electrode. See Figure 4-6 and Figure 4-7. 4. Reinstall the spark plug into the cylinder head. Torque spark plug...

  • Page 60: Air Cleaner Service

    4.4 Air Cleaner Service Air Cleaner Service Use the following procedure to replace the paper WARNING element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator set Risk of fire.

  • Page 61: Air Cleaner, 20 Kw Models

    Note: Operating the engine with loose or damaged air retaining knobs. cleaner components could allow unfiltered air into the engine causing premature wear and 7. When element replacement is necessary, order failure. genuine Kohler parts. TP-7092 8/18 Section 4 Scheduled Maintenance...

  • Page 62: Cooling System

    4.5 Cooling System 4.7 Battery The engine fan draws cooling air through the openings WARNING 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 discharged at the exhaust outlet.

  • Page 63: Cleaning The Battery

    4.7.3 Checking Specific Gravity Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s Use a battery hydrometer to check the specific gravity of instructions for battery maintenance. the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb All generator set models use a negative ground with a at the top of the electrolyte level or the number adjacent...
  • Page 64 Tempera- Correction ture   71.1 + .032 + .030 65.6 + .028 EXAMPLE NO. 1— + .026   Temperature below 80 F (26.7 60.0 + .024 + .022 Hydrometer Reading 1.250 54.4 + .020   Acid Temperature 20 F (- -6.7 + .018 Subtract .024 Specific Gravity...

  • Page 65: Storage Procedure

    4.8 Storage Procedure 4.8.3 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 66 Notes Section 4 Scheduled Maintenance TP-7092 8/18...
  • Page 67 Figure 5-1 USB Port and Mini-Breaker Locations MainPwrOverL Shutdown, is displayed if this internal protection is activated. Press OFF to reset. Contact an authorized Kohler distributor/dealer for service. 5.3.2 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.
  • Page 68 5.5 Thermostat Procedure to Reset the Thermostat 1. Disconnect the utility power to the generator by WARNING opening (turning OFF) the corresponding circuit breaker at the building’s distribution panel. 2. Open the enclosure roof and secure it with the roof stay on the left side of the enclosure.
  • Page 69 5.6 Troubleshooting Figure 5-3 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Troubleshooting Table Problem 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.
  • Page 70 Troubleshooting Table Problem Possible Cause Corrective Action Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if Generator set stops suddenly. necessary. No fuel. Check fuel valves and fuel supply. Model 20RCA/20RCAL only: Check enclosure thermostat and reset if tripped.
  • Page 71 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline flat head machine (screw)
  • Page 72 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 73 Notes TP-7092 8/18...
  • Page 74 Notes TP-7092 8/18...
  • Page 76 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7092 8/18 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2018 by Kohler Co. All rights reserved.

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