Kohler 14RCA Installation Manual
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Kohler 14RCA Installation Manual

Residential/commercial generator sets
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Residential/Commercial Generator Sets
Installation
Models:
14RCA
14RCAL
20RCA
20RCAL
Controller:
RDC2
TP-7091 2/21a

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Summary of Contents for Kohler 14RCA

  • Page 1 Installation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL Controller: RDC2 TP-7091 2/21a...

  • 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...

  • Page 3: Table Of Contents

    ............2.2.1 Fuel Conversion, Original Fuel System, 14RCA/RCAL ... . .
  • Page 4 Table of Contents, continued 5.7.4 Oil Pressure Sensor Boot ........Section 6 Drawings and Diagrams .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, WARNING can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 6 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 7 Fuel System Propane (LPG)—Adequate ventilation DANGER is mandatory. Because propane is heavier than air, install propane gas WARNING detectors low in a room. Inspect the detectors manufacturer’s instructions. Natural Gas—Adequate ventilation is Hazardous voltage. Moving parts. mandatory. Because natural gas rises, Will cause severe injury or death.
  • Page 8 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 9: Introduction

    Accessory Literature Information in this publication represents data available User Guide, OnCue Plus TP-7006 at the time of print. Kohler Co. reserves the right to Technical Manual, OnCue Plus TP-7007 change this publication and the products represented without notice and without any obligation or liability...

  • Page 10: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7952 Fax: (86) 10 6518 7955 Look at the labels and decals on your Kohler product East China Regional Office, Shanghai or review the appropriate literature or documents Phone: (86) 21 6288 0500 included with the product.

  • Page 11: Section 1 Location And Mounting

    Do not use lifting eyes. Lift the generator set using lifting bars Have the generator set installed by an authorized Kohler inserted through the lifting holes on distributor/dealer or authorized representative. For all the skid.

  • Page 12: Generator Set Inspection

    Model Weight, kg (lb.)* 14RCA 200 (440) 20RCA 252 (555) * Weights include generator set and packaging with skid; no battery or ATS.

  • Page 13: Location And Mounting

    1.4 Location and Mounting area at least 1.2 m (4 ft.) beyond the exhaust end of the generator set. See the dimension drawing in Section 6. Install the generator set outdoors near the incoming gas The generator set is shipped on an aluminum base. Set service.

  • Page 14: Access The Air Intake Area

    1.6 Access the Air Intake Area 3. To make the electrical connections, you will also need to remove the cover panel over the terminal The battery, fuel system, and some electrical block as shown in Section 3.1.4. connections are located in the air intake area. Remove 4.

  • Page 15: Section 2 Fuel

    Fuel supply inlet 1/2 NPT Explosive fuel vapors can cause severe injury or death. Fuel supply pressure, kPa (in. H Take additional precautions when using the following fuels: 14RCA/RCAL 1.2- 2.7 1.7- 2.7 Propane (LPG)—Adequate ventilation mandatory.

  • Page 16: Fuel Pipe Size

    (8 ft.) to the measured length for each 90 degree elbow. Compare the total pipe length with the chart in Figure 2-3 to find the required pipe size. Contact local LPG provider for LPG installation information. Minimum Gas Pipe Size Recommendation, in. NPT 14RCA/RCAL 20RCA/RCAL Natural Natural Pipe Length,...

  • Page 17: Fuel Conversion

    Remove the negative (- ) lead first personal (laptop) computer and Kohler SiteTech when disconnecting the battery. software to change the setting. Reconnect the negative (- ) lead last when reconnecting the battery.

  • Page 18: Fuel Conversion, Original Fuel System, 14Rca/Rcal

    LPG, remove the NG fitting and install the LPG fitting as described below. See Figure 2-6 for the fuel system component locations. Ignition Timing Lead Connection, 14RCA/L only 1. Ignition timing leads (14RCA/L only) 2. Fuel hose and clamp 3.
  • Page 19 Procedure to Convert from NG to LPG, 14RCA/L Conversion from LPG to Natural Gas, 14RCA/L 1. Press the OFF button on the generator set To convert from LPG to natural gas, repeat the steps controller. above, removing the LPG fuel orifice and installing the NG fitting.

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

    2.2.2 Fuel Conversion, Original Fuel Conversion from LPG to Natural Gas, 20RCA/L System, 20RCA/RCAL To convert from LPG to natural gas, repeat the steps above to remove the LPG fuel orifice. 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.

  • Page 21: Fuel Conversion, Revised Fuel System

    2.2.3 Fuel Conversion, Revised Fuel Fuel Selection, Revised Fuel System System 1. Press the OFF button on the generator set controller. The revised fuel system uses a knob that controls a valve on the regulator to select the fuel type. See 2.
  • Page 22 14. Press the OFF button to shut down the generator set. Img_0900 Figure 2-12 Knob Position, LPG 6. On 14 kW models, find the ignition timing leads 65 and N, located near the regulator. See Figure 2-13. a. For natural gas (NG), connect lead 65 to lead b.

  • Page 23: Section 3 Electrical

    Section 3 Electrical 3.1 Electrical Connections Have an authorized distributor/dealer or a licensed electrician make the following electrical connections. The electrical installation must comply with the National DANGER Electrical Code (NEC) class 1 wire designation and all applicable local codes. Canadian installations must comply with the Canadian Electrical Code (CEC) and applicable local codes.

  • Page 24: Grounding

    3.1.2 Grounding Various regulations and site configurations including the National Electrical Code (NEC), local codes, and the Ground the generator set. The grounding method type of transfer switch used in the application determine must comply with NEC and local codes. Connect the the grounding of the neutral at the generator.

  • Page 25: Field Connections

    3.1.4 Field Connections Customer connection points are located as shown in Figure 3-3. 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.

  • Page 26: Ac Power Supply

    6. For connection of optional accessories, including 3.1.5 AC Power Supply the programmable interface module (PIM), and/or The installer must connect AC power for the battery a load shed kit, see Section 3.3.2. charger (which is integral to the RDC2 controller) and Note: Connect the shield on the outside of the the optional accessories shown in Figure 3-4.

  • Page 27: Battery

    3.2 Battery Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the WARNING neutralizing solution.
  • Page 28 Battery Description Battery Installation Procedure Starting batteries are usually the lead-acid type. Use a 1. Ensure that the starting battery is fully charged 12-volt group 51 battery with a minimum rating of 500 before placing the battery in service. cold cranking amps at 0 F. The generator set uses a 2.

  • Page 29: Ats And Accessory Communication Connections

    3.3 ATS and Accessory For the longer cable runs shown in the last two rows of Figure 3-6, use 12 or 14 AWG cable for PWR and Communication Connections COM, and use the 20 AWG communication cable specified above for the A and B connections only. In following sections cover...
  • Page 30 RXT* Generator Set RBUS 12 VDC Note: Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS. * RXT transfer switch with standard or combined interface/ load management board. 1. Generator set terminal block. See Figure 3-3 for location. Check the decal on the generator set for terminal block connections. 2.

  • Page 31: System Connections With Accessory Modules

    3.3.3 System Connections with maximum cable lengths with 1, to 4 modules per cable run. Accessory Modules Note: A model RXT transfer switch with combined See Figure 3-9 through Figure 3-13 for connection interface/ load management board acts as two options to RBUS accessory modules.
  • Page 32 Generator Set 12VDC RBUS Load Shed Kit RXT* Note: See Section 3.3.1, Communication Cable Specifications for maximum cable lengths. * RXT transfer switch with standard or combined interface/load management board. Do not use a load shed kit with a combined interface board. 1.
  • Page 33 Generator Set RXT ATS Terminal Block Load Notes: Shed See Figure 3-3 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. See Section 3.3.1, Cable Specifications (3 runs with 1 module each shown).
  • Page 34 Generator Set RXT ATS Terminal Block Notes: See Figure 3-3 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. See Section 3.3.1, Cable Specifications. See Figure 3-9 for communication connection detail (A Load and B, PWR and COM).

  • Page 35: Section 4 Prestart

    Section 4 Prestart 4.1 Prestart Installation Check Review the previous installation sections. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following DANGER Prestart Checklist. Prestart Checklist Air Cleaner. Check that a clean air cleaner element is installed to prevent unfiltered air from entering the Hazardous voltage.

  • Page 36: Set The Exerciser

    In order to set a loaded exercise using the RDC2 Manual for more detailed instructions to set the date and controller, a Kohler Model RXT transfer switch must be time and set the exerciser. connected. See the generator set operation manual for instructions to set a loaded exercise.

  • Page 37: Section 5 Accessories

    Section 5 Accessories 5.1 Introduction Figure 5-4 shows the location for the carburetor heater kit on a 20 kW generator set. This section describes some of the accessories that are Verify that AC power is connected to the generator set available for the generator sets.
  • Page 38 adv-8954 Detail view: tp6195 1. Carburetor heater (air cleaner removed to show heater) 2. Carburetor heater power cord Figure 5-3 Carburetor Heater for 14 kW Models tt1482b 1. Carburetor heater location under air cleaner. Insert from the back of the generator set. 2.

  • Page 39: Programmable Interface Module (Pim)

    The default settings for the inputs and outputs are shown in Figure 5-7. To change the input and output settings, use a personal computer running Kohler SiteTech software. See TP-6701, SiteTech Software img1061 Operation Manual, for instructions.

  • Page 40: Oncue Plus Generator Management System

    5.4 OnCue Plus Generator PIM Connection Factory Default Setting Management System Input 1 None Input 2 None The OnCue Plus Generator Management System Output 1 (Relay 1) allows monitoring and control of your generator set from a personal computer, smart phone, or tablet. OnCue Output 2 (Relay 2) Common Fault Plus can also be configured to send email or text...

  • Page 41: 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 recomended. Two relays are included on the load management...

  • Page 42: Power Relay Module

    Operation/Installation Manual for the Model RXT transfer switch. The PowerSync Automatic Paralleling Module (APM) allows the use of two Model 14RCA or two 20RCA generator sets in a single-phase paralleling system to supply power to one building or site. See Figure 5-11.

  • Page 43: Cold Weather Package

    Operating the heater before installation can cause burns and component damage. equipment must be installed by a Kohler trained and Disconnect power to the heater and allow it to cool before authorized distributor or dealer.

  • Page 44: Breather Tube And Oil Heater

    Note: The heaters require a continuous source of AC power. See Figure 5-14 and Figure 5-15 for the power supply voltage required. Note: The breather tube heater and oil heater must be used together. Verify that AC power is connected to the generator set as described in the generator set Installation Manual.

  • Page 45: Alternator Weather Cover

    2. Heating probe 5. 120 VAC male connector (connect to breather tube heater) 3. Thermostat Figure 5-17 Oil Heater Note: For Models 14RCA(L): If the generator set is 5.7.3 Alternator Weather Cover equipped with a carburetor heater, obtain kit The alternator weather cover is used to prevent frost GM102228-S to replace the breather tube, air and snow build up on the alternator brushes.
  • Page 46 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).
  • Page 47 Section 6 Drawings and Diagrams Figure 6-1 lists the drawing numbers and page numbers. Dimension Drawings Drawing Number Page 14/20RCA/RCAL 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 48 Figure 6-2 Dimension Drawing ADV-9746, Sheet 1 Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 49 Figure 6-3 Dimension Drawing, ADV- 9746, Sheet 2 TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 50 Figure 6-4 Dimension Drawing, ADV-9746, Sheet 3 Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 51 Figure 6-5 Dimension Drawing ADV-9746, Sheet 4 TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 52 Figure 6-6 Dimension Drawing ADV-9746, Sheet 5 Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 53 Figure 6-7 Schematic Diagram, ADV-9236, Sheet 1 TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 54 Figure 6-8 Schematic Diagram, ADV-9236, Sheet 2 Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 55 Figure 6-9 Schematic Diagram, ADV-9236, Sheet 3 TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 56 Figure 6-10 Schematic Diagram, ADV-9236, Sheet 4 Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 57 Figure 6-11 Wiring Diagram GM115458 Sheet 1, Single Phase, 2-Pole Circuit Breaker TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 58 Figure 6-12 Wiring Diagram GM115458 Sheet 2, Single Phase, 1-Pole Circuit Breaker Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 59 Figure 6-13 Wiring Diagram GM115458 Sheet 3, Three Phase, 3-Pole Circuit Breaker TP-7091 2/21 Section 3 Diagrams and Drawings...
  • Page 60 Notes Section 3 Diagrams and Drawings TP-7091 2/21...
  • Page 61 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 62 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 64 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7091 2/21a For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com 2018 Kohler Co. All rights reserved.

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