Installation Residential/Light Commercial Generator Sets Models: 24RCL Controller: RDC2 TP-6906 6/14
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. 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.
Table of Contents Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 4 Section 4 Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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. Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: Propane (LP)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room.
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.
Introduction This manual provides installation instructions for the Model 24RCL and 30RCLH generator sets. Operation manuals are available separately. See Figure 1 for an illustration of the 24RCL generator set. 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.
Service Assistance For professional advice on generator power requirements and conscientious service, please contact your nearest authorized Kohler distributor/dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KOHLERPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Section 1 Installation Instructions 1.1 Introduction Review this entire section and the Safety Precautions before starting the installation procedure. The generator set specification sheet also contains data that may be required during the installation process. The generator set and accessories must be installed by an authorized Kohler distributor/dealer or authorized representative. The installation must comply with the National Electrical Code (NEC), state, and local codes.
Tools Required: D Multimeter (for measuring voltage and current) D Frequency meter (may be part of multimeter) D Manometer (for measuring fuel pressure) D Torque wrench D Wrenches D Screwdrivers D Socket wrenches or nut drivers D Pliers D Safety glasses or goggles D Drill with bits and hole saw 1.2 Lifting Generator Set WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes.
and effective lift. Consideration needs to be given to, but not necessarily limited to the following items: d Weight and center of gravity of the equipment being lifted d Weight and center of gravity of the lifting device d Boom angles d Selection of rated rigging d Stability of lifting foundation d Wind and weather conditions d Local or regional codes that may require or restrict types of rigging.
1.3 Location and Mounting 1.3.1 Location Factors The manufacturer recommends mounting the generator set on concrete at ground level. For installations suspended above ground level, including roof installations, weight considerations are especially important. The building engineer must determine whether the structure can support the weight of the generator set.
1.3.4 Prepare Site Choose a location that is at least 0.9 m (3 ft.) from any building or structure and near the incoming gas service. Allow a minimum of 2.4 m (8 ft.) clearance beyond the exhaust end of the generator set. Plan the installation so that the exhaust outlets of the generator set are not directed toward the building or any openings where exhaust gas could be drawn into the building. Install carbon monoxide detectors on each level of any building adjacent to the generator set.
1.4 Electrical System DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. 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. WARNING Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.
1.4.1 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Most field-installed accessory kits include installation instructions. Comply with applicable national, state, and local codes when installing a wiring system. For Canadian installations, refer to the Canadian Electrical Code (CEC). Row Temp.
1.4.2 Terminal Connector Torque Use the torque values shown in Figure 1-7 or Figure 1-8 for terminal connectors. Refer to UL-486A, UL-486B, and UL-486E for information on terminal connectors for aluminum and/or copper conductors. Comply with applicable national, state, and local codes when installing a wiring system.
1.4.3 Ground and Neutral Connections Ground the generator set. The grounding method must comply with NEC and local codes. Connect the grounding strap to the generator set ground lug, terminal GRD inside the junction box (see Figure 1-10). Connect the grounds for utility and low voltage connections to the ground lugs provided in the customer connection box for those specific connections (see Figure 1-10).
1.4.6 Connect AC and DC Wiring Note: Have a licensed electrician make the following electrical connections. All connections must comply with state and local codes. Size the wire according to the length of run and 115% of the circuit current (amperage) based on 75_C wire rating or less as directed by the National Electrical Coder (NEC) in ANSI/NFPA 70. See Section 1.4.1 for additional information about wire selection.
Generator Set Connections Use separate conduit for the power cables and the low voltage communication or engine start leads. Local codes and the length of run as well as the transfer switch wire size requirements will determine the wire size needed for the AC leads. Note: Some codes require the use of a disconnect switch. Check the code requirements for your location and install a disconnect switch, if required. 1.
1.4.7 Automatic Transfer Switch Connection 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.
Kohler Model RXT Automatic Transfer Switch The RDC2 controller is designed to control the Kohler Model RXT transfer switch as well as the generator set. Follow the installation instructions to connect the transfer switch interface board to the appropriate terminals on the generator set. The RDC2 controller uses a Kohler-propietary communication protocol to communicate with the transfer switch.
Engine start connection for other transfer switches or a remote start/stop switch Note: Do not use the Kohlerr Model RRT transfer switch with Model RCL generator sets. Other Kohler transfer switches, inckuding Model RDT, RSB, and Model K (MPACt) transfer switches can be used with the Kohler generator sets covered in this document. These transfer switches contain separate ATS controls that do not communicate with the RDC2 controller.
1.4.8 Communication Cable Specifications PWR and COM Connections RBUS Connections A and B For the RBUS communication connections A and B to the Model RXT transfer switch, optional PIM, and/or optional LCM or load shed kit, use 20 AWG shielded, twisted-pair communication cable. Belden #9402 (two-pair) or Belden #8762 (single-pair) or equivalent cable is recommended.
1.4.9 System Connections with Accessory Modules one programmable interface module (PIM), and/or one load control module (LCM). See Figure 1-14 through Figure 1-18 for connection options with up to three accessory modules. Accessory modules can include one Model RXT transfer switch, See Section 1.4.8 for cable size and length specifications. 1 2 Generator Set GND 12VDC RBUS 4 COM PWR 3 RXT B A A A B B PWR PWR COM COM PIM A A B B PWR PWR COM COM LCM A B PWR COM 5 1. 2. 3. 4. 5.
Generator Set 2 GND 12VDC RBUS 4 COM 3 PWR RXT B A 1 A A B B PWR PWR COM COM 5 PIM A A B B PWR PWR COM COM 6 A B Note: See Section 1.4.8, Cable Specifications. 1. 2. 3. 4. 5. 6. PWR LCM COM Customer connection terminal block. See Figure 1-10 for location. Check the decal on the generator set for terminal block connections. Connect one end of each cable shield to GROUND at the generator set.
Generator Set RXT ATS Customer Connection Terminal Block LCM Notes: D See Figure 1-10 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. D See Figure 1-13 for maximum total cable length per run (3 runs with 1 module each shown). PIM D See Figure 1-14 for communication connection detail. D Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block. See Figure 1-17.
Generator Set RXT ATS TB1 PIM Notes: D See Figure 1-10 for terminal block location on generator set. Check the decal on the generator set for terminal block connections. LCM D See Figure 1-13 for maximum total cable length with 12 or 14 AWG wire. D See Figure 1-14 for communication connection (A and B, PWR and COM) details. Connect the cable shield to ground at the generator set. tp6809 Figure 1-18 Accessory Module Connections (two cable runs with one and two modules shown) 1.4.
1.5 Engine Starting 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 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.
1.6 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. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children.
1.6.1 Fuel Lines Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow. Use the pipe size indicated in Figure 1-19 for the total length of pipe. Gas lines. Never use fuel piping to ground electrical equipment. The gas supplier is responsible for installation, repair, and alteration to gas piping. Use Schedule 40 black-iron pipe for gas piping.
1.6.2 Gas Regulators Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines. See the generator set specification sheet for fuel supply pressure requirements. Primary gas regulator. The primary regulator reduces the high pressure from a tank or transmission line to the lower pressure required by the secondary regulator on the engine. The fuel supplier provides the primary regulator.
1.6.4 Fuel Conversion Procedures The generator set is easily configurable for use with either NG or LPG. System configuration for NG or LPG requires a mechanical setting on the fuel pressure regulator and an electrical connection on the wiring harness. These adjustments will ensure that the proper fuel and spark timing are supplied to the engine. Note: The fuel pressure regulator is factory preset for NG. When using NG, no mechanical adjustment is required.
1.7 Cooling System WARNING Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. The generator set is equipped with a unit-mounted radiator common cooling system. Add cooloant before starting the generator set. The system’s major components include two electric fans, a circulating water pump, a radiator, and a thermostat.
6. Add coolant to the radiator to just below the overflow tube on the filler neck. See Figure 1-24. 7. Replace the radiator’s pressure cap. 8. Maintain the coolant level in the coolant overflow bottle between the Hot and Cold markings. See Figure 1-24 for the coolant overflow bottle location. Coolant Capacity, L (gal.) Engine Model 24RCL, 30RCLH 12.4 (13.1) Figure 1-23 Coolant Capacity 1 2 1.8 Prestart Installation Check Review the entire installation section.
1.9 Set Exerciser 1.10 Operation Tests 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. Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks. Figure 1-25 shows the controller screens. 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.
Notes 38 Section 1 Installation Instructions TP-6906 6/14
Section 2 Accessories 2.1 Introduction Accessories are available factory-installed and/or shipped loose. Obtain the most current list of accessories from the generator set specification sheet or by contacting an authorized Kohler distributor/ dealer. Have accessories installed by your local authorized Kohler distributor/dealer or authorized representative. Follow the installation instructions provided with each kit.
2.3 Programmable Interface Module (PIM) 2.3.2 The optional Programmable Interface Module (PIM) provides two programmable inputs and six dry contact outputs, four of which are programmable. The PIM with enclosure is shown in Figure 2-2. See TT-1584 for PIM installation and connection instructions. The PIM is mounted in a NEMA 3R aluminum enclosure, which can be mounted indoors or outdoors. See Section 1.4.
2.4 Load Control Module (LCM) The Load Control Module is available for single-phase generators sets only. The Load Control Module monitors and prioritizes non-essential residential loads based on the available power from the generator set. As the load on the generator set decreases or increases, loads are added or shed in the order of their priority.
2.5 OnCue Plus Generator Management System Ethernet cable to the cable in the customer connection box. The OnCuer Plus Generator Management System 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. Both a network cable connection (OnCue Plus) and a wireless version (OnCue Plus Wireless) are availabe.
Section 3 Generator Reconnection 3.1 Voltage Reconnection The reconnection procedure explains voltage reconnections only. Do not attempt to change the frequency (e.g. from 60 Hz to 50 Hz) in the field. The following instructions explain the reconnection of 12-lead generator sets. In all cases, follow the National Electrical Code (NEC) guidelines. Reconnect the stator leads of the generator set if a different output phase or voltage is desired. Refer to the following procedure and the connection schematics.
3.2 Four-Lead (Single-Phase) Generator Sets 3.3 12-Lead (Three-Phase) Generator Sets Figure 3-1 shows the factory connection for the singlephase 120/240 V 60 Hz generator set. Four-lead, single-phase models are not reconnectable. Three-phase, 12-lead generator sets are reconnectable to the voltages and phases shown on the generator set specification sheet.
ADV-5875E-P Figure 3-2 12-Lead Generator Reconnection, 24RCL and 30RCLH TP-6906 6/14 Section 3 Generator Reconnection 45
3.4 Changing System Settings The RDC2 controller’s keypad and display allow the installer to check and change the generator system settings, if necessary. The system settings for each generator model are set at the factory and should not normally require changes. Check the genset system settings and change them, if necessary, after generator reconnection or controller replacement. The following procedure explains how to change the system settings. The procedure is also illustrated in Figure 3-5.
Status Displays System voltage, frequency, and phase adjustments are in the Genset System menu. Overview ----> 1.2 h Engine ----> Metering ATS ----> Configuration * Generator----> Metering Date ----> and Time Genset ----> Information Network ----> Information Genset ----> Run Time PIM Status ----> Genset System ----> Load Control ----> ATS Status ----> Event Log----> * ATS configuration appears only if a Model RXT transfer switch is connected.
Changing System Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. Press: Display: Overview 1.2 h ----> Press: 2. Press the down arrow button to navigate to the Genset System menu. See Figure 3-4. Press: Display: Genset System ----> 3. Press the Select button to enter the genset system menu. Press: Display: System Voltage: 240 V 4. Press the down arrow button, if necessary, to step to the setting that you want to change. 5.
3.5 Voltage Calibration 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. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.
Generator ----> Metering Three-phase Single-phase Volts L1--L2: 240 V Calibrate Volts L2--L3: 240 V Calibrate Volts L3--L1: 240 V Volts: 240V Frequency: 60.0 Hz Calibrate To Calibrate Voltage: 1. Press Select when the voltage is displayed. The voltage flashes. Calibrate 2. Press the Up or Down arrow button to change the setting. 3. Press the Select button to save the setting. Frequency: 60.0 Hz 4. Press the down arrow button to move to the next menu.
3.5.2 Calibration Using SiteTech Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. Connect a personal computer (laptop) to the controller using a USB cable and follow this procedure to use Kohlerr SiteTecht software to calibrate the controller. The voltage calibration factors are located in the Genset Calibration group in SiteTecht. Find the parameter labelled Genset Calibration Factor Voltage, L1--L2. See Figure 3-8.
# 1 1.
Section 4 Diagrams and Drawings This section contains dimension drawings, wiring diagrams, and schematics for the enclosed generator set. Figure 4-1 lists the drawing numbers and page numbers. Drawings are arranged in numerical order on the following pages. See the generator set Operation Manual for service views, if necessary.
Figure 4-2 Schematic Diagram, 24RCL Generator Set, ADV-8554, Sheet 1 of 2 54 Section 4 Diagrams and Drawings TP-6906 6/14
Figure 4-3 Schematic Diagram, 24RCL Generator Set, ADV-8554, Sheet 2 of 2 TP-6906 6/14 Section 4 Diagrams and Drawings 55
Figure 4-4 Dimension Drawing, 24RCL and 30RCLH, ADV-8641, Sheet 1 of 2 56 Section 4 Diagrams and Drawings TP-6906 6/14
Figure 4-5 Dimension Drawing, 24RCL and 30RCLH, ADV-8641, Sheet 2 of 2 TP-6906 6/14 Section 4 Diagrams and Drawings 57
Figure 4-6 Wiring Diagram, 24RCL Generator Set, GM92458, Sheet 1 of 2 58 Section 4 Diagrams and Drawings TP-6906 6/14
Figure 4-7 Wiring Diagram, 24RCL Generator Set, GM92458, Sheet 2 of 2 TP-6906 6/14 Section 4 Diagrams and Drawings 59
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. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 TP-6906 6/14 E 2014 by Kohler Co. All rights reserved. For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call 1-800-544-2444 or visit KOHLERPower.
