Residential/Commercial Generator Sets - Solar Panels · PDF file ·...

Residential/Commercial Generator Sets

Models:

8/10/12RESV8/10/12RESVL

Controllers:

RDC2DC2

TP-6880 10/14a

Operation

Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm.

WARNINGCalifornia Proposition 65

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model DesignationSpecification NumberSerial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator setoperation manual, spec sheet, or sales invoice.

Controller Description

Engine IdentificationRecord the product identification information from theengine nameplate.

ManufacturerModel DesignationSerial Number

Table of Contents

TP-6880 10/14 Table of Contents

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Descriptions and Service Views 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Engine 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Generator Set Enclosure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Alternator 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Transfer Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Controllers 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7 OnCue Plus Generator Management System 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8 Accessories 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8.1 Carburetor Heater 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8.2 Programmable Interface Module (PIM) 16. . . . . . . . . . . . . . . . . . . . . . . . . . .1.8.3 Load Control Module (LCM) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8.4 Load Shed Kit 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 Service Views 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Generator Set Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Prestart Checklist 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Exercising the Generator Set 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Generator Set Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 Local Starting and Stopping 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.2 Automatic Starting and Stopping 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.3 Remote Starting and Stopping 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.4 Engine Start Crank Cycle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.5 Engine Cooldown 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.6 Automatic Operation with Model RXT Transfer Switch 21. . . . . . . . . . . . . .2.3.7 Automatic Operation with Other Transfer Switches 22. . . . . . . . . . . . . . . . .

2.4 Exercise 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.1 Setting the Exerciser 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics 22. . . . . . . .2.4.3 Unloaded Full-Speed Exercise 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.4 Loaded Full-Speed Exercise (with RXT only) 23. . . . . . . . . . . . . . . . . . . . . .2.4.5 Power Failure During Exercise Cycle 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Faults 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1 Warnings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2 Shutdowns 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 ATS Communication Errors 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.4 Resetting the Controller after a Fault Shutdown 24. . . . . . . . . . . . . . . . . . . .

2.6 Generator Enclosure Thermostat 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 RDC2 Controller Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 RDC2 Generator Set/ Transfer Switch Controller 29. . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Controls and Indicators 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Controller Keypad 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 LED Indicators 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 LCD Display 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Controller Power 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Battery Charging 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Changing Settings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 Setting the Exerciser 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 Setting the Exerciser at Controller Power-up 34. . . . . . . . . . . . . . . . . . . . . .3.6.2 Changing the Exercise Settings 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 RDC2 Controller Menus 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Main Menu 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Overview Menu 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10 Engine Metering Menu 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11 Generator Metering Menu 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12 Generator Set Information Menu 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13 Genset Run Time Menu 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6880 10/14Table of Contents

3.14 Genset System Menu 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15 ATS Status Menu 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16 ATS Configuration Menu 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17 Date and Time Menu 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18 Networking Information Menus 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.18.1 Networking Status Submenu 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18.2 Networking Configuration Submenu (OnCue Plus Password) 45. . . . . . . .3.18.3 RBUS Information 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18.4 Remote Devices Submenu 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.19 Programmable Interface Module (PIM) Status Menu 49. . . . . . . . . . . . . . . . . . . . . . . .3.20 Load Control Module (LCM) or Load Shed Kit Menus 50. . . . . . . . . . . . . . . . . . . . . . .3.21 Event Log 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 DC2 Controller Operation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 DC2 Generator Set/ Transfer Switch Controller 53. . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Controls and Indicators 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Controller Keypad 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 LED Indicators 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.3 LCD Display 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Controller Power 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Battery Charging 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Exercise 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Exercise Modes 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.2 Setting the Exerciser 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.3 Exerciser Reset 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Event Log 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.7 Maintenance Timer 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8 OnCue Plus Password 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Scheduled Maintenance 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Scheduled Maintenance 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Service Schedule 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Lubrication System 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Low Oil Pressure Shutdown 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 Oil Check 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.3 Engine Oil Recommendation 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.4 Oil Change Procedure 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.5 Resetting the Maintenance Timer 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Spark Plugs 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Air Cleaner Service 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Air Cleaner, 8RESV/RESVL Models 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.2 Air Cleaner, 10/12RESV/RESVL Models 66. . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Cooling System 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 Exhaust System 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7 Battery 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8 Storage Procedure 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.1 Lubricating System 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8.2 Fuel System 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8.3 Cylinder Lubrication 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8.4 Exterior Preparation 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8.5 Battery 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Troubleshooting 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Introduction 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 USB Port 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Fault Messages 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Circuit Protection 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Controller Internal Circuit Protection 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4.2 Line Circuit Breaker 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4.3 Auxiliary Winding Circuit Breaker 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Troubleshooting 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6880 10/14 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Battery

Sulfuric acid in batteries.Can cause severe injury or death.

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Battery acid cancausesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as this may result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

TP-6880 10/146 Safety Precautions and Instructions

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetal surface away from thebattery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Fire.Can cause severe injury or death.

Do not smoke or permit flames orsparks near fuels or the fuel system.

WARNING

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the carburetor, fuel line,fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors.Catch fuels in an approved containerwhen removing the fuel line orcarburetor.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding. Never operate the generatorset where exhaust gas could seepinside or be drawn into a potentiallyoccupied building through windows, airintake vents, or other openings.

Carbon monoxide detectors.Carbon monoxide can cause severenausea, fainting, or death. Installcarbon monoxide detectors on eachlevel of any building adjacent to thegenerator set. Locate the detectors toadequately warn the building’soccupants of the presence of carbonmonoxide. Keep the detectorsoperational at all times. Periodicallytest and replace the carbon monoxidedetectors according to themanufacturer’s instructions.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

TP-6880 10/14 7Safety Precautions and Instructions

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LP vapor gas ornatural gas fuel system for leakage byusing a soap and water solution withthe fuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

Welding the generator set.Can cause severe electricalequipment damage.

Never weld components of thegenerator set without firstdisconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM).

CAUTION

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

TP-6880 10/148 Safety Precautions and Instructions

Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on thegenerator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) connectors. (3) Disconnect allgenerator set controller and voltageregulator circuit board connectors.(4) Disconnect the engine battery-charging alternator connections.(5) Attach the weld ground connectionclose to the weld location.

Connecting the battery and thebattery charger. Hazardous voltagecan cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

Hot Parts

Hot engine and exhaust system.Can cause severe injury or death.

Do not work on the generator set untilit cools.

WARNING

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Servicing the engine heater. Hotparts can cause minor personalinjury or property damage. Install theheater before connecting it to power.Operating the heater before installationcan cause burns and componentdamage. Disconnect power to theheater and allow it to cool beforeservicing the heater or nearby parts.

NoticeNOTICE

Canadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

TP-6880 10/14 9Introduction

Introduction

This manual provides operation and maintenanceinstructions for residential/commercial model8/10/12RESVandRESVLgenerator sets equippedwithKohler RDC2 or DC2 generator set/transfer switchcontrollers. See Figure 1. The RDC2 and DC2controllers control the generator set and the optionalModel RXT transfer switch.

This generator set is approved for use in stationaryapplications in locations served by a reliable utilitypower source. Have the generator set installed by anauthorized distributor/dealer or service technician.Refer to TP-6879, Installation Manual, for installationinstructions.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment service requirements are very importantto safe and efficient operation. Inspect the parts oftenandperform requiredserviceat theprescribed intervals.Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Figure 1 RESV/RESVL Generator Set

List of Related LiteratureFigure 2 identifies related literature available for thegenerator sets covered in thismanual. Only trained andqualified personnel should install or service thegenerator set.

Generator Set Literature Part Number

Installation Manual, Model8/10/12RESV/RESVL Generator Set TP-6879

Transfer Switch Literature

Operation/Installation Manual, ModelRXT Automatic Transfer Switch TP-6807

Operation/Installation Manual, ModelRDT Automatic Transfer Switch TP-6345

Installation Manual, Model RSBAutomatic Transfer Switch TP-6486

Operation Manual, Model RSBAutomatic Transfer Switch TP-6487

Accessory Literature

Operation Manual, OnCuer PlusSoftware TP-6928

Operation Manual, SiteTecht Software TP-6701

Installation Instructions, Load ControlModule (LCM) TT-1574

Installation Instructions, ProgrammableInterface Module (PIM) TT-1584

Instructions, Firmware Update UsingUSB Utility TT-1636

Instructions, Load Shed Kit TT-1609

Figure 2 Related Literature

TP-6880 10/1410 Introduction

NameplateThe following illustration shows a typical generator setnameplate. Copy the model, serial, and specificationnumbers from thenameplate into thespacesprovided inthe product information section on the inside front coverof this manual. See the service views in Section 1.9 forthe nameplate location.

GM12070

Emission InformationThe Kohlerr Model SV620 engine used on the8RESV/RESVL generator set is certified to operateusing natural gas or propane fuel.

The Kohlerr Model KT725 engine used on the10RESV/RESVL and 12RESV/RESVL generator set iscertified to operate using natural gas or propane fuel.

The Emission Compliance Period referred to on theEmissionControl orAir Index label indicates thenumberof operating hours for which the engine has been showntomeet CARB or EPA emission requirements. Figure 3provides the engine compliance period (in hours)associated with the category descriptor, which may befound on the certification label.

Emission Compliance Period

EPA Category C250 hours

Category B500 hours

Category A1000 hours

CARB Moderate125 hours

Intermediate250 hours

Extended500 hours

Figure 3 Emission Compliance Period

Refer to the certification label for engine displacement.

The exhaust emission control system for the SV620engines (8RESV/RESVL) is EM for U.S. EPA,California, and Europe.

The exhaust emission control system for the KT725engine (10RESV/RESVL and 12RESV/RESVL) is EMfor U.S. EPA, California, and Europe.

Generator Set ApplicationKohlerr Power Systems (KPS) ensures that all Kohlerrgenerator sets are certified to applicable standards fortheir intended application. It is the owner/operator’sresponsibility to operate Kohlerr generator setsexclusively according to the directions provided in theaccompanying operation manuals.

Kohlerr generator sets designated as StationaryStandby, Emergency or Emergency Standby may onlybe operated for emergency power generation and formaintenance/testing. Emergency power generation islimited to power production when electric power from alocal utility (or the normal power source, if the facilityruns on its own power production) is interrupted.

The US Clean Air Act explicitly prohibits usingEmergency Standby generators as a primary electricpower source regardless of whether a site is connectedto the electrical grid. Emergency Standby generatorsmay NOT be used to power sites which are notconnected to an electric utility. The U.S. Clean Air Actauthorizes owner/operator fines of up to $3,750 per dayof operation in violation of the generator set’scertification.

Owners/operators should familiarize themselves withand perform all testing, maintenance, notification,reporting and record keeping as required by the CleanAir Act. In most cases, performance testing is notrequired if the generator is operated and maintainedaccording to the operation manual. However,owners/operators must retain maintenance records.

TP-6880 10/14 11Service Assistance

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat the labels and stickers on yourKohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6880 10/1412 Service Assistance

Notes

TP-6880 10/14 13Section 1 Descriptions and Service Views

Section 1 Descriptions and Service Views

1.1 IntroductionThe generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegenerator set servicemanual, engineoperationmanual,and engine servicemanual for additional specifications.Obtain copies of the latest spec sheets, manuals,diagrams, and drawings from your local distributor/dealer.

1.2 EngineThe 8RESV generator set has a four-cycle, singlecylinder, air-cooled Kohlerr engine and 10/12RESVgenerator sets have a four-cycle, twin cylinder,air-cooled Kohlerr engine. The engines operate onclean-burning natural gas or LPG. Engine featuresinclude:

D Efficient overhead valve design and full pressurelubrication for maximum power, torque, and reliabilityunder all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of partssubjected to the most wear and tear.

D Field-convertible multi-fuel systems that allow fuelchangeover fromnatural gas to LPG(andvice- versa)while maintaining EPA emission certification.

1.3 Generator Set EnclosureThegenerator set is housed ina steel enclosurewhich isdipped in e-coat for extra corrosion protection andpainted with a durable powder coat finish. Theenclosure has a hinged, locking roof that allows easyaccess to the generator set controller when required,but locks securely to prevent unauthorized access.

To open the roof, insert the tool provided with theenclosure and turn counterclockwise 1/4 turn. Then justraise the roof. The roof stays open until you are ready toclose it.

Be sure to close and lock the enclosure, and keep thetool in a secure location.

1.4 AlternatorThe generator uses Kohler’s unique PowerBoosttvoltage regulation system, which provides instantresponse to load changes.

PowerBoostt ensures reliable motor starting andconsistent voltage levels. PowerBoostt utilizes avoltage excitation system that employs a windingindependent of the main output windings to provideexcitation voltage.

1.5 Transfer SwitchThe RDC2 and DC2 controllers are designed tointerface with and control the Kohler Model RXTAutomatic Transfer Switch (ATS). Do not use the KohlerModel RRT transfer switch with the RDC2 or DC2controller.

If the power system uses a different model transferswitch, theRDC2andDC2controllerswill not control thetransfer switch. An ATS other than the Model RXTmustbe equippedwith a transfer switch controller and enginestart contacts that connect to the remote engine startterminals on the generator set.

1.6 ControllersRESV models are equipped with the RDC2. RESVLmodels use the DC2. See Figure 1-1.

The controller provides integrated control for thegenerator set, Kohlerr Model RXT transfer switch,programmable interfacemodule (PIM), and load controlmodule (LCM) or load shed kit.

The controller’s 2-line LCD screen displays statusmessages and system settings that are clear and easyto read, even in direct sunlight or low light.

RDC2 (RESV) DC2 (RESVL)

Figure 1-1 Controllers

TP-6880 10/1414 Section 1 Descriptions and Service Views

RDC2 Controller FeaturesD Six-button keypad

d OFF, AUTO, and RUN pushbuttons

d Select and arrow buttons for access to systemconfiguration and adjustment menus

D LED indicators for OFF, AUTO, and RUN modes

D LED indicators for utility power and generator setsource availability and ATS position (Model RXTtransfer switch required)

D LCD display

d Two lines x 16 characters per line

d Backlit display with adjustable contrast forexcellent visibility in all lighting conditions

D Scrolling system status display

d Generator set status

d Voltage and frequency

d Engine temperature

d Oil pressure

d Battery voltage

d Engine runtime hours

D Date and time displays

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintainsteady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load tofull-load

D Automatic start with programmed cranking cycle

D Programmable exerciser can be set to startautomatically on any future day and time, and runevery week or every two weeks

D Exercise modes

d Unloaded weekly exercise with complete systemdiagnostics

d Unloaded full-speed exercise

d Loaded full-speed exercise (Model RXT ATSrequired)

D Front-access mini USB connector for SiteTechtconnection or the Kohler USB utility

D Integral Ethernet connector for Kohlerr OnCuerPlus

D Built-in 2.5 amp battery charger

D Remote two-wire start/stop capability for optionalconnection of Model RDT or RSB transfer switches

D Diagnostic messages

d Displays diagnostic messages for the engine,generator, Model RXT transfer switch,programmable interface module (PIM), and loadcontrol module (LCM) or load shed kit

d Over 70 diagnostic messages can be displayed

D Maintenance reminders

D System settings

d System voltage, frequency, and phase

d Voltage adjustment

d Measurement system, English or metric

D ATS status (Model RXT ATS required)

d Source availability

d ATS position (normal/utility oremergency/generator)

d Source voltage and frequency

D ATS control (Model RXT ATS required)

d Source voltage and frequency settings

d Engine start time delay

d Transfer time delays

d Voltage calibration

d Fixed pickup and dropout settings

D Programmable Interface Module (PIM) statusdisplays

d Input status (active/inactive)

d Output status (active/inactive)

D Load control module (LCM) or load shed kit menus

d Load status

d Test function


DC2 Controller FeaturesD Four-button keypad: OFF, AUTO, RUN, andEXERCISE pushbuttons

D LED indicators for OFF, AUTO, and RUN modes

D LCD display:

d Two lines x 16 characters per line

d Backlit display with adjustable contrast forexcellent visibility

D Scrolling system status display

d Generator set status

d Voltage and frequency

d Engine temperature

d Oil pressure

d Battery voltage

d Engine runtime hours

d Maintenance reminders

d OnCuer Plus status (connected/disconnected)

D Date and time displays

D Smart engine cooldown senses engine temperature

D Digital isochronous governor to maintainsteady-state speed at all loads

D Digital voltage regulation: ±0.5% RMS no-load tofull-load

D Automatic start with programmed cranking cycle

D Exercise modes

d Unloaded weekly exercise with complete systemdiagnostics

d Unloaded full-speed exercise

d Loaded full-speed exercise (Model RXT ATSrequired)

D Front-access mini USB connector for SiteTechtconnection or the Kohler USB utility

D Integral Ethernet connector for KohlerrOnCuerPlus

D Built-in 2.5 amp battery charger

D Remote two-wire start/stop capability for optionalconnection of Model RDT or RSB transfer switches

D Diagnostic messages

d Displays diagnostic messages for the engine,generator set, model RXT transfer switch, andoptional programmable interface module (PIM)and load control module (LCM) or load shed kit

d Over 70 diagnostic messages can be displayed

D A laptop computer and Kohlerr SiteTech softwarecan be used to change system settings

D A laptop computer and Kohlerr SiteTech software orKohler USB Utility software can be used to updatecontroller firmware

See the generator set Installation manual for moreinformation.

1.7 OnCue Plus GeneratorManagement System

The OnCuer Plus Generator Management Systemcomes included with your generator and allowsmonitoring and control of your generator set from apersonal computer, smart phone, or tablet. OnCuerPlus can be configured to send email or text messagenotifications in the event of a generator set fault. SeeTP-6928, OnCuerPlus SoftwareOperationManual, forsoftware instructions.


1.8 AccessoriesThe following optional accessories are offered for theRESV and RESVL generator sets.

1.8.1 Carburetor Heater

An optional carburetor heater is recommended forimproved cold starting in locations where the ambienttemperature drops below 0_C (32_F). The carburetorheater prevents condensation and carburetor icing. Theheater requires a continuous source of 120 VACpower.

1.8.2 Programmable Interface Module(PIM)

The optional Programmable Interface Module (PIM)provides two programmable inputs and sixprogrammable dry contact outputs for connection tocustomer-supplied equipment. The outputs arecontrolled by the RDC2 controller, and can also becontrolled remotely using the OnCuer Plus program.

ThePIM ismounted inaNEMA3Raluminumenclosure,which can be mounted indoors or outdoors. See theinstallation instructions provided with the PIM.

1.8.3 Load Control Module (LCM)

The optional Load Control Module (LCM) provides anautomatic load management system to comply withSection 702.5 of NEC 2008. The installer is responsiblefor ensuring that the power system installation complieswith all applicable state and local codes.

The LCM automatically manages up to six residentialloads. Four power relays are provided for managementof non-essential secondary loads, and two relays areavailable to control two independent air conditionerloads.

The LCM is controlled by the RDC2/DC2 controller. Theload on the generator set is monitored, and loads areadded or shed in the order of their priority. Seespecification sheet G6-120 and the LCM installationinstructions for more information.

1.8.4 Load Shed Kit

The optional LoadShedKit functions in a similar fashionas the Load Control Module (LCM) and provides anautomatic load management system to comply withSection 702.5 of NEC 2008. The installer is responsiblefor ensuring that the power system installation complieswith all applicable state and local codes.

The Load Shed Kit automatically manages up to sixresidential loads, four customer-supplied power relaysand two relays to control two independent airconditioner loads.

The Load Shed Kit is controlled by the RDC2/DC2controller. The load on the generator set is monitored,and loads are added or shed in the order of their priority.See specification sheet G11-124 and installationinstructions TT-1609 for more information.

Either a Model RDT or Model RXT transfer switch isrequired for the load shed kit installation. The load shedkit mounts inside the Model RDT or Model RXT transferswitch enclosure and is available for single-phasegenerators sets only.

Note: Do not install both a load shed kit and a loadcontrol module (LCM) on the same system.


1.9 Service Views

7

8

11

19

2

9

6

ADV-8539

10

18

5

1. Hinged roof2. Air cleaner3. Nameplate location4. Thermostat5. Engine starting battery location (battery purchased separately)6. Gas regulator assembly and fuel selector valve7. Fuel solenoid valve8. Fuel inlet9. Field-connection terminal block and 20 amp resettable circuit

breaker (behind panel)

10. Line circuit breaker11. 120 VAC receptacles for optional carburetor heater (not shown)12. Lock13. Locking tool, provided with generator set14. USB port15. RDC2 or DC2 controller16. Oil check (dipstick) and oil fill17. Oil drain valve18. Oil filter19. Muffler

15

17

14

3

16

1

12

13

4

Figure 1-2 Service View


21

2220

20. Lifting holes21. Air intake

22. Exhaust outlet

Figure 1-3 Service View

TP-6880 10/14 19Section 2 Generator Set Operation

Section 2 Generator Set Operation

2.1 Prestart Checklist



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

TP-6880 10/1420 Section 2 Generator Set Operation



WARNING

Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbonmonoxideis a poisonous gas present in exhaust gases. Carbonmonoxide is an odorless, colorless, tasteless, nonirritating gasthat can cause death if inhaled for even a short time. Carbonmonoxide poisoning symptoms include but are not limited tothe following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles


D Stomachache, vomiting, nauseaIf experiencing any of these symptoms and carbon monoxidepoisoning is possible, seek fresh air immediately and remainactive. Do not sit, lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. Seek medicalattention if the condition of affected persons does not improvewithin minutes of breathing fresh air.

Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is anodorless, colorless, tasteless, nonirritating gas that can causedeath if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Neveroperate the generator set inside a building. Never operate thegenerator set where exhaust gas could seep inside or bedrawn into a potentially occupied building throughwindows, airintake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbonmonoxide detectors on each level of any building adjacent tothe generator set. Locate the detectors to adequately warn thebuilding’s occupants of the presence of carbon monoxide.Keep the detectors operational at all times. Periodically testand replace the carbon monoxide detectors according to themanufacturer’s instructions.



DANGER

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or appliances when standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Connecting the battery and the battery charger.Hazardous voltage can cause severe injury or death.Reconnect the battery correctly, positive to positive andnegative to negative, to avoid electrical shock and damage tothe battery charger and battery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardous voltage/current can causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

To ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverification after the unit starts.

Air Cleaner. Check for a clean and installed air cleanerelement to prevent unfiltered air from entering theengine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

Exhaust System. Check for exhaust leaks andblockages. Check the muffler condition.

D Inspect the exhaust system components for cracks,leaks, and corrosion. Check for tight exhaust systemconnections.

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is unobstructed.

Oil Level. Check the oil level before starting thegenerator set and at the intervals given in Section 5,Scheduled Maintenance. Maintain the oil level at ornear, not over, the full mark on the dipstick.

Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.


2.2 Exercising the Generator SetOperate the generator set without load once each weekfor 20 minutes. See Section 2.4 for information aboutloaded and unloaded exercise modes. For instructionsto set the exerciser, see:

D Section 3.6 for the RDC2 controller

D Section 4.5 for the DC2 controller

2.3 Generator Set Operation

2.3.1 Local Starting and Stopping

Start: Press the RUN button to immediately start thegenerator set.

Stop: Press the OFF button. The engine stops.

Run the generator set with no load for at least 2 minutesto ensure adequate engine cooldown.

2.3.2 Automatic Starting and Stopping

An automatic transfer switch monitors the utility powerand signals the generator set to start when utility poweris lost. The ATS then transfers the load to the generatorset.

When utility power is restored, the transfer switchtransfers the load back to utility, runs the generator setwith no load to cool down the engine, and then stops thegenerator set.

2.3.3 Remote Starting and Stopping

A remote switch connected to terminals 3 and 4 can beused to start and stop the generator set. Close theswitch to start and run the generator set. Open theswitch to stop the generator set.

Run the generator set with no load for at least 2 minutesto ensure adequate engine cooldown.

2.3.4 Engine Start Crank Cycle

The controller attempts to start the generator set threetimes (three crank cycles, 15 seconds crank and15 seconds off). If the generator set does not start inthree attempts, the system shuts down on an overcrankfault. See Section 2.5.

Cranking 1, 2, and 3 are displayed during the crankcycle. Pressing the OFF button during the crank cyclestops the cranking. No other buttons are acknowledgedduring the crank cycle.

2.3.5 Engine Cooldown

The engine cooldown time delay allows the engine torun after the loads have been removed.

The engine cooldown time delay is set to 5minutes. Theengine stops before the cooldown time delay expires ifthe temperature drops below the cooled-downtemperature level, or if the temperature rises above thehigh limit during the cooldown cycle.

If a transfer switch other than theModel RXT is used, anadditional engine cooldown time delay may beprogrammed on the transfer switch. To allow the smartengine cooldown on the RDC2/DC2 controller tooperate most efficiently, set the cooldown time on thetransfer switch controller to zero or the minimum timeallowed. Refer to the instructions provided with thetransfer switch for more information.

2.3.6 Automatic Operation with ModelRXT Transfer Switch

The Model RXT transfer switch connects to theRDC2/DC2 controller through the ATS interface boardon the transfer switch. Also see theModel RXTTransferSwitch Operation/Installation Manual for moreinformation about transfer switch operation.

The controller must be in AUTO mode for automatictransfer switch operation.

Automatic Start

TheRDC2/DC2controller receivesutility sourcevoltagesensing data from the Model RXT transfer switch.

1. If the utility source voltage falls below anacceptable level, the controller starts the enginestart time delay.

2. If the utility source is not restored before the timedelay expires, the generator set starts.

3. After the Normal-to-Emergency time delay, theATS is signaled to transfer the load to theemergency source.

Automatic Stop with Engine Cooldown

1. When the utility source is restored, theEmergency-to-Normal time delay starts.

2. When the Emergency-to-Normal time delayexpires, the load is transferred to the utility.

3. The generator set runs through the enginecooldown cycle and then stops.


2.3.7 Automatic Operation with OtherTransfer Switches

If a transfer switch other than the Model RXT (such as aKohler Model RDT or RSB) is used, the engine startcontacts from the ATS must be connected to enginestart leads 3 and 4 on the generator set.

The controller must be in AUTO mode to respond toremote start/stop signals from an ATS or remote switch.Press the AUTO button to put the controller intoautomatic mode.

Automatic Start

The engine start contacts on the ATS close to signal thegenerator set to start, and remain closed while thegenerator set is running.

Automatic Stop

The engine start contacts on the ATS open to signal thegenerator set to stop.

2.4 ExerciseThe RDC2 and DC2 controllers can be set toautomatically run thegenerator set at the same timeandday each week. Exercising the generator set weekly orevery two weeks is required to keep the engine andalternator in good operating condition.

Three exercise modes are available: unloaded cycle,unloaded full speed, and loaded full speed. SeeSections 2.4.2 through 2.4.4 for information about theexercise modes. A loaded exercise can be set at theRDC2 controller only if a Model RXT transfer switch isconnected.

Note: With transfer switches other than theModel RXT,it is possible to have two exercise settings (oneunloaded exercise set at the generator setcontroller, and another exercise set at the ATScontroller). If the exercise times overlap, the ATSexercise setting takes priority.

If a transfer switch other than the Model RXT is used,refer to the instructions providedwith the transfer switchto set a loaded exercise at the ATS, if desired.

2.4.1 Setting the Exerciser

When power is applied to the RDC2 controller (that is,when the battery is connected), you will be prompted toset the date and time, and then to set the exerciser.

The first setting will flash. Press the Up and Down arrowbuttons to change the setting. Press Select to save thesetting and move on to the next. See Section 3.5 for

more detailed instructions to change settings on theRDC2. See Section 3.6 for more detailed instructions toset the exerciser or change the exercise settings.

The DC2 controller does not prompt you to set theexerciser. See Section 4.5 for instructions to set theexerciser on the DC2.

2.4.2 Unloaded Cycle Exercise withComplete System Diagnostics

An unloaded exercise runs the generator set withoutsignalling the transfer switch to transfer the electricalload from the utility source to the generator set. TheUnloaded Cycle exercise with diagnostics is therecommended exercise mode and is the defaultexercise setting.

The Unloaded Cycle exercise runs the engine for 20minutes in the cycle shown in Figure 2-1 and describedbelow.

D Runs at reduced speed for 10 minutes to warm upand exercise the engine.

D Ramps up and runs at full speed for 3 minutes.Engine diagnostics are performed during thisfull-speed portion of the cycle, which provides thebest test of engine and alternator power backupcapability. Diagnostic tests at full speed can identifypotential problemswith the power output and alert theoperator before an emergency event.

D Ramps down and runs at reduced speed for 5minutes to cool down theenginebefore shuttingdownautomatically.

EngineSpeed,R

PM

EngineExercise

Full-SpeedDiagnostics

Cooldown

3 min.

1 min.1 min.

10 min. 5 min.

Figure 2-1 Unloaded Exercise Cycle


System Diagnostics

During the unloaded exercise, the controller monitorsthe following data. The controller display indicates thatthe generator set is running, unless a fault is detected asdescribed below.

D ATS connection. The controller verifies that theModel RXT ATS interface board is connected.

D Battery voltage. Battery voltage is checked beforeexercise to verify engine starting capability. Batteryvoltage provides a measurement of battery health. Ifthe controller detects low battery voltage, thecondition is indicated on the display.

D Communication integrity tests. J1939, RBUS,Ethernet, and USB are monitored for messagesindicating that the controller and wiring are reliable.

D Engine speed. Engine speed is measured atreduced speed and full speed. An overspeed orunderspeed condition will result in a fault conditionand shutdown.

D Generator output frequency and voltage.Operating the generator at full speed allows theRDC2/DC2 controller to check the output power forcorrect voltage, frequency, and stability. When theengine is running at full speed, the controller verifiesthat the voltage and frequency are within acceptablelimits. A fault message is displayed if the voltage orfrequency is out of range.

D Oil pressure. Oil pressure is verified to ensureproper lubrication of critical engine components.Pressure is monitored at both reduced and fullspeeds. If the oil pressure is low, the LowOil Pressuremessage is displayed and the generator set shutsdown.

2.4.3 Unloaded Full-Speed Exercise

Theunloaded full-speedexercise runs thegenerator setat full speed for 20minuteswithout transferring the load.

To set an unloaded full-speed exercise, follow theprocedure in Figure 3-8 and select Exercise Mode:Unloaded Full.

2.4.4 Loaded Full-Speed Exercise (withRXT only)

A loaded exercise starts the generator set, ramps up tofull speed, and then transfers the electrical load from theutility source to the generator set. After 20 minutes, theload is transferred back to the utility source. The engineruns without load for 5 minutes or until cool, and thenshuts down automatically.

Note: With a loaded exercise, power to the building islost for up to 10 seconds during load transfer.

For a loaded exercise controlled by the RDC2 or DC2controller, a Model RXT transfer switch must beconnected to the generator set. To set a loadedexercise, follow the procedure in Figure 3-8 and selectExercise Type: Loaded.

For a loaded exercise with a transfer switch other than aKohlerr Model RXT, program the exercise at thetransfer switch controller. Refer to the transfer switchoperation manual for instructions.

2.4.5 Power Failure During ExerciseCycle

If the utility power is lost during an unloaded exercise,theATS transfers to theemergencysource, theexerciseis ended and the control remains in the AUTO mode.

If the utility power is lost during a loaded exercise, theexercise is ended. The ATS remains in the emergencyposition and the control goes into the AUTO mode.

The generator set continues to run and supply power tothe load for the duration of the utility power outage.WhenUtility power is restored, theATSwill re-transfer tothe utility source through normal timing sequences.


2.5 FaultsThe RDC2/DC2 controller displays fault messages forgenerator set warnings and shutdowns. Selected faultmessages are shown in Figure 2-3.

2.5.1 Warnings

The controller displays a fault message but thegenerator set does not shut down on a warning. Thecontroller resets automatically after a warning conditionis corrected.

2.5.2 Shutdowns

Under a fault shutdown condition, the generator setshuts down automatically and the controller displays afault message. The OFF LED flashes. In some cases,the engine cooldown cycle runs before the engine shutsdown. See Figure 2-3.

Shutdown switches (such as the low oil pressure switchor high engine temperature switch) on the generator setwill automatically reset when the problem is corrected.However, the fault condition at the controller does notclear until the controller is reset.

The generator set cannot be restarted until the faultcondition is corrected and the controller is reset. SeeSection 2.5.4 for instructions to reset the controller aftera fault shutdown.

2.5.3 ATS Communication Errors

When aModel RXT transfer switch is used, an ATS faultindicates that the connection to the interface board onthe transfer switch has been lost. Check the connectionto the ATS interface board.

2.5.4 Resetting the Controller after aFault Shutdown

Always identify and correct the cause of a faultshutdownbefore resetting the controller. Check the faultmessage displayed on the controller and refer toFigure 2-3 to identify and correct the fault conditionbefore proceeding. Contact an authorizeddistributor/dealer for service, if necessary.

RDC2 Controller

Press theOFFbutton to reset the controller, or follow theprocedure below. See Figure 2-2.

1. While the fault message is displayed, press theSelect button to go to the Overview menu.

2. Press Select again. The active fault message isdisplayed.

3. PressSelect.ConfirmClearFault:NO isdisplayed.

4. Press the Down arrow button. ConfirmClear Fault:YES is displayed.

5. Press the Select button to enter YES and clear thefault.

6. Press the Select button to return to the overviewmenu. The controller changes to OFF mode.

7. PressAUTO to put the generator set into automaticmode.

DC2 Controller

Press the OFF button to clear the fault message on thecontroller.

Overview ---->1.2 h

Fault Message

tp6809

Confirm ClearFault: NO

Confirm ClearFault: YES

Fault Message

Press Up arrow button.

Figure 2-2 Clearing a Fault on the RDC2 Controller


Fault MessageWarning (W) orShutdown (SD) Condition Check

AC Sens Loss W (1 sec.)

SD (3 sec.) *

AC sensing lost. In Auto mode, generator outputAC sensing is lost. Detection begins 10 secondsafter crank disconnect.

Warning: after 1 second if no output detectedafter crank disconnect.

Shutdown: after 3 seconds if voltage waspresent and then lost.

Contact an authorizeddistributor/dealer for service.

Accy PwrOverWarning

W Accessory Power Overload. An over current fault(short circuit) on the accessory controller poweroutput.


Alt Protect SD High generator current has been detected. Thegenerator set shuts down to protect thealternator from damage caused by overheatingthe windings (10RESV and 12RESV only).

Reduce the load.

ATS ComError W ATS communication error. Warning is displayedif ATS interface connection is lost.See Section 2.5.3.

Check communication wiring betweentransfer switch interface board andgenerator set.

ATS PhaseRot W ATS phase rotation mismatch. Transfer switchphase rotation does not match, ATS will nottransfer.

Correct the ATS connection. Refer tothe ATS Installation manual, wiringdiagrams, and labels on the transferswitch.

Aux Input SD * Auxiliary input. An optional customer-connectedinput is closed. (Digital input from optional PIM.)

Check customer-supplied equipment.

Batt Chg Flt W Battery charger fault. Input to PIM from anexternal battery charger (not the built-in batterycharger).

Check external battery charger.

Battery High W Engine starting battery voltage rises above 16VDC for more than 10 seconds. Inhibited duringthe engine crank cycle.

Clears when the battery voltage returns to anacceptable level.

Check the battery rating andcondition.

Check the battery charger operation.

Battery Low W Engine starting battery voltage falls below 12.5VDC for more than 90 seconds when the engineis not running. Not operative during the enginecrank cycle.




Charge or replace the battery.

Battery CrLoWarning

W Engine starting battery voltage falls below 11Volts for more than 10 seconds. Inhibited duringthe engine crank cycle.





Eng SpeedHigh

SD * Engine speed exceeds 115% of the normalrunning speed for more than 0.3 seconds.


Eng Speed Low SD * Engine speed drops below 85% of the normalrunning speed for more than 3 seconds.

Reduce the load.


Exer Not Sch W Exercise not scheduled. No exercise isscheduled on the controller.

See Section 3.6 or 4.5 for instructionsto set the exerciser.

* Engine cooldown runs before shutting down.


FaultWarning (W) orShutdown (SD) Condition Check

Frequency High SD * Governed frequency exceeds 110% of thesystem’s frequency setpoint for more than 10seconds. Function becomes active 10 secondsafter engine start (10 second inhibit).


Frequency Low SD * Governed frequency falls below 90% of thesystem frequency setting for more than10 seconds, or 1 Hz below the system frequencysetting for more than 60 seconds.

Function becomes active 10 seconds afterengine start (10 second inhibit).

Reduce the load and restart thegenerator set.


Lo Crank Vlt W Low cranking voltage. Battery voltage falls below8 VDC for more than 6 seconds while the starteris engaged.


MainPwrOverL SD Main power overload. An over current fault onthe 70 controller power output (short circuit).


Check for shorted run relay.

Check wiring for short circuits.

Not in Auto W The generator set is not in Automatic (standby)mode. Remote start and stop commands from atransfer switch or remote switch will be ignored.

Press AUTO to place the generatorset in Automatic mode, whenappropriate.

Oil Pres Low SD * The LOP switch indicates low oil pressure formore than 5 seconds. Function becomes active30 seconds after crank disconnect (30 secondinhibit).

Note: The low oil pressure shutdown does notprotect against low oil level. Check the engine oillevel regularly as recommended in Section 5.

Check for leaks in the lubricationsystem.

Check the oil level and add oil if thelevel is low.

Check the oil pressure switch andwiring

Over Crank SD Three unsuccessful starting attempts. Check the fuel supply, spark plug,and battery.

Reset the thermostat.

Check for loose connections.


Spd Sens Flt SD Engine speed sensor has failed or enginestalled.


Total PowerHigh

SD Measured load is greater than 102% of thegenerator set power rating for more than 1minute (10RESV and 12RESV only).

Reduce the load.

Volts L1-L2High

SD * Generator voltage high. Output voltage exceeds120% of the system nominal voltage for morethan 2 seconds.


Volts L1-L2 Low SD * Generator voltage low. Output voltage fallsbelow 80% of the nominal system voltage formore than 10 seconds.

Reduce the load and restart thegenerator set.


* Engine cooldown runs before shutting down.

Figure 2-3 Controller Fault Messages


2.6 Generator EnclosureThermostat

8RESV(L), 10RESV(L), and 12RESV(L) generatorsinclude a resettable thermostat in the air intakecompartment. The thermostat detects excess heatinside the enclosure. If the thermostat trips, thegenerator will shut down and the controller will display afault (underspeed, underfrequency, or undervoltage). Ifthe thermostat trips for some reason other than hightemperature (i.e. a nuisance trip), follow these steps toreset the thermostat.

1. Disconnect the utility power to the generator byopening (turning OFF) the corresponding circuitbreaker at the building’s distribution panel.

2. Open the enclosure roof.

3. Press the button on the thermostat to reset it. SeeFigure 2-4 for the thermostat location.

4. Reconnect utility power to the generator set byclosing the circuit breaker in the distribution panel.

5. Reset the fault on the RDC2/DC2 controller. SeeSection 2.5.4.

1

1. Thermostat

Figure 2-4 Thermostat Location


Notes

TP-6880 10/14 29Section 3 RDC2 Controller Operation

Section 3 RDC2 Controller Operation

3.1 RDC2 Generator Set/ TransferSwitch Controller

Model RESV generator sets are equipped with theRDC2 generator set/transfer switch controller.

Model RESVL generator sets are equipped with theDC2 controller. See Section 4 for DC2 controlleroperation information.

The RDC2 controls the following power systemcomponents:

D Model 8RESV, 10RESV, or 12RESV generator set

D Model RXT Automatic Transfer Switch (ATS)

D Load Control Module (LCM) or load shed kit

D Programmable Interface Module (PIM)

The RDC2 controller features include:

D Two-line x 16 character backlit digital display withadjustable contrast

D OFF, AUTO, and RUN generator set master controlbuttons

D Generator set status indicating LEDs (OFF, AUTO,RUN)

D Up, Down, and Select buttons for navigation throughmenus and adjustments

D Power system indicator LEDs to show utility andgenerator source status, and to show which source(utility or generator) is supplying power to the load

3.2 Controls and IndicatorsFigure 3-1 illustrates the RDC2 controller. SeeFigure 3-2 for details of the controller’s user interface.

1. User Interface; see Figure 3-22. USB port (mini-B); see Section 6.2.

1

2

GM77569

Figure 3-1 RDC2 Controls and Indicators

1. 2-line LCD display2. Up button3. Select button4. Down button5. RUN button and LED6. Generator power available LED*7. Building on generator power LED*8. Building on utility power LED*9. Utility power available LED*10. OFF button and LED11. AUTO button and LED

* These LEDs operate only if a Model RXT transfer switch isconnected.

1

10

3

2

5

11

4

GM77569

6789

Figure 3-2 RDC2 User Interface

TP-6880 10/1430 Section 3 RDC2 Controller Operation

3.2.1 Controller Keypad

TheRUN,OFF, andAUTObuttonscontrol thegeneratorset as described in Figure 3-3.

Use the Select, Up arrow, and Down arrow buttons tonavigate through the menus and change settings, ifnecessary. See Section 2.3 for operation instructions.

3.2.2 LED Indicators

LEDs above the RUN, OFF, and AUTO buttons indicatethe mode of operation as shown in Figure 3-4.

Power System LEDs indicate the status of the utilitypower and the generator set, and indicate which sourceis supplying power to the building (based on the positionof the RXT transfer switch). See Figure 3-2 andFigure 3-4.

Note: The power system LEDs operate only if a ModelRXT transfer switch is connected. They will notoperate if a different transfer switch is used.

Button Button Function

RUN Starts the generator set. The engine start time delay is ignored.

OFF Stops the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing OFF will stop the crank cycle.

Press OFF to clear faults and reset the controller.

AUTO Places the generator set in Automatic (standby) mode.

Down arrowUse to navigate through menus and change settings. This manual contains instructions to navigate thecontroller menus and adjust settings on the RDC2 controller.Select

Up arrow

Figure 3-3 RDC2 Controller Pushbutton Operation

LED LED Operation

RUN Lights when the generator set has been started locally by pressing the RUN button.Remote start and stop commands are ignored.

OFF Lights for 2 seconds, then flashes every 2 seconds when the generator set andcontroller are off. Remote start/stop commands have no effect. The exercise cycle willnot run.

In Auto mode, OFF LED flashes quickly to indicate a fault shutdown. Attention required.Identify and correct the fault condition before resetting the controller.

AUTO Lights when the generator is in automatic (standby) mode. Generator set will respond toengine start and stop commands from the controller (for example, exercise start andstop commands) or an ATS. Time delays operate as described in Section 2.3.

Utility Power Available * Lights when utility power is available.

Building on Utility Power * Lights when the building load is connected to utility power through the RXT transferswitch.

Generator Power Available * Lights when generator power is available.

Building on Generator Power * Lights when the building load is connected to generator power through the RXT transferswitch.

* These LEDs operate only if a Model RXT transfer switch is connected.

Figure 3-4 RDC2 Controller LED Operation


3.2.3 LCD Display

The controller is equipped with a two-line x 16 characterbacklit digital displaywith adjustable contrast.When thegenerator is running, the controller automatically scrollsthrough the displays shown in Figure 3-5. When thesystem is in AUTO, the screens shown in Figure 3-6 aredisplayed.

When a fault or warning condition exists, the controllerwill show the corresponding message. See Section 2.5for more information about faults.

Controller menus display power system information,including status information for the engine, generator,and optional RBUS accessories, exercise settings, andevent history. Some menus allow changes to thecontroller settings. See Sections 3.7 through 3.21 formenu diagrams.

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Genset StatusRunning

Voltage: 240VFreq: 60.0Hz

Engine: 123FOil Pressure: OK

Battery12.3V

Engine Runtime:12345.6 h

Date: 02DEC2011Time: HR:MNpm

Active Alert

Sample data shown.

Figure 3-5 Autopaging Displays, Generator Running

The display contrast is adjustable. Navigate to theGenset System menu and step down to the Contrastscreen.Press theSelect button, and thenuse theupanddown arrow buttons to adjust the contrast. See Section3.5, Changing Settings, and Section 3.14, GensetSystem Menu.

The display backlight turns off after about aminute of noactivity. The backlight turns onwhen a button is pressedor when the generator set starts.

tp6804

Battery12.3V



Next Exercise:09:00p 09Dec2011

Next Maintenance:150 h or Mar2012

Sample data shown.

Genset StatusStandby

Active Alert

Figure 3-6 Autopaging Displays, Automatic Mode


3.3 Controller PowerThe RDC2 controller is powered by the generator setengine starting battery and the built-in battery charger.

Note: To disconnect controller power, disconnect theutility power to the generator set and disconnectthe battery .

If controller power is disconnected and reconnected,youwill be prompted to set the time, date, and exerciser.The first setting will flash. Press the Up and Down arrowbuttons to change the setting. Press Select to save thesetting andmove on to the next. Repeat until all settingsare saved and the controller returns to the main menu.SeeSection 3.5 formore detailed instructions to changesettings on theRDC2. SeeSection 3.6 formore detailedinstructions to set the exerciser or change the exercisesettings.

3.4 Battery ChargingThe controller includes a built-in battery charger tomaintain the engine starting battery. The RDC2controller monitors the battery voltage and provides aconstant 14.0 ±2% VDC voltage and maximum 2.5amps to charge the battery.

The installer must connect 120 VAC/60Hz utility powerprovided from thebuildingonabreaker-protectedcircuitfor the built-in battery charger.

3.5 Changing SettingsSome settings can be changed from the controllerkeypad.Thecontroller settingsandgenerator set outputare factory-set and should not require field adjustmentunder normal circumstances. Check and adjust thesettings and/or output when:

D The controller has been replaced.

D The voltage requires adjustment for a particularapplication.

D Troubleshooting generator set problems.

Havecontroller setupandadjustmentperformedonlybyan authorized Kohler distributor/dealer or authorizedrepresentative.

The following procedure explains how to changesettings. See Figure 3-7 for an example using the Dateand Time settings.

Note: Use caution when navigating the controllermenus. In some menus, pressing the Selectbutton can enable editing of the controllersettings. Changing the settings to incorrectvalues can adversely affect generator setoperation or render the unit inoperable.

Procedure to Change Settings

1. Press the Select button to enter the main menu.

2. Press thedownarrowbuttonuntil thedesiredmenuis displayed. The Genset Systemmenu is used forthis example. See Figure 3-9.

3. Press the Select button to enter the genset systemdisplays. See Figure 3-7.

4. Press the down arrow button to step through thegenerator set system settings.

5. To changeanyof the genset systemsettings, pressthe Select button. The selected setting flashes.

6. Press the up or down arrow buttons to increase ordecrease the setting.

7. When the desired setting is shown, press Select.The value stops flashing. If there are additionaladjustable settings on the screen, the next settingflashes. For example, in the date menu, the day,month, and year can be adjusted.

8. Repeat steps 6 and 7 for each setting on thescreen.

9. Press the down arrow to step to the next screen.

10. To exit, press the down arrow button until Return isdisplayed.Press theSelect button toexit themenu.

11. Press the AUTO or OFF button to exit the mainmenu.

Note: If no buttons are pushed, the controller exits themenus and returns to the generator set statusdisplay after 5 minutes.


1. Press the Select button to enter the main menu.

2. Press the down arrow button until the desiredmenu is displayed. SeeFigure 3-9.Date andTimeare used for this example.

3. Press theSelect button to enter theDate andTimemenu.

4. To change the date and time settings, press theSelect button again. The year will flash.

5. Press the up or down arrow buttons to change theyear.

6. When the correct year is shown, press the Selectbutton. The year is saved and the next setting(month) flashes.

7. Repeat steps 5 and 6, using the arrow and selectbuttons to set the month and the date.

Press:

Changing Settings on the RDC2 Controller

Press: Display:Overview ---->

1.2 h

Display:

Press: Display:

Press: Display:

Date ---->

and Time

Date:

05Dec2011

8. When the correct date is shown, press the Selectbutton. The saved date is shown.

9. Press the down arrow button to step to the nextmenu.

10. Repeat steps 5 and 6, using the arrow and selectbuttons to set and save the time.

Note: To change from am to pm, press the up arrowkey to increase the hour until the correct hourand pm is displayed.

11. In the time format menu, press Select and thenpress the up or down arrow button to change theformat, 12 hr. or 24 hr. Press Select to save thedisplayed format.

12. Press the down arrow button. Return isdisplayed.

13. Press Select to return to the Date and Timemenu.

14. Press the Up or Down arrow buttons to step to adifferent menu.

15. Press Auto to signal the controller to exit themenus and return to the generator set statusdisplay.

Note: If no buttons are pressed, the controller returnsto the status display after 5 minutes.

Press: Display:OR

Press: Display:

Press: Display:<---- Return

Press: Display:

Time:

01:49pm

Date ---->

and Time

AUTO

Press: Display:Genset State

Standby

Date:

05Dec2011

Date:

05Dec2012

Press: Display:Date:

05Dec2012

Press: Display:Date:

03Jan2012

Figure 3-7 Changing Settings


3.6 Setting the ExerciserSet the exerciser to automatically run the generator setfor 20 minutes every week or every two weeks.

3.6.1 Setting the Exerciser at ControllerPower-up

When battery power is connected to the controller, youwill be prompted to set the date and time, and then to setthe exerciser.

The first setting will flash. Press the Up and Down arrowbuttons to change the setting. Press Select to save thesetting and move on to the next. See Section 3.5 formore detailed instructions to change settings on theRDC2.

If the battery is disconnected and reconnected duringgenerator set maintenance or service, the time, date,and exercise settings will need to be re-entered.

3.6.2 Changing the Exercise Settings

This section explains how to change the exercisesettings after the initial setup.

Follow the procedure below and see the flowchart inFigure 3-8 to set the exercise time and date, mode, andfrequency.

Procedure to Set the Exerciser

1. Press the AUTO button on the controller.

2. Press the Select button to go to the main menu.See Figure 3-9.

3. Press the down arrow button to step to the GensetSystem menu.

4. Press theSelect button to enter theGenset systemmenu. See Figure 3-8.

5. Use the down arrow button to step to the NextExercise menu. If the exerciser is not set, NoExercise Scheduled will be displayed.

6. Press and HOLD the Select button to enableediting.

7. Press the Select button. The setting flashes toshow that it can be changed. For example, HRflashes to show that the hour can be changed.

8. Press the Up or Down arrow buttons to change thesetting.

9. Press the Select button to save the setting andmove to the next. For example, save HR settingand move to MN.

10. Repeat steps 5 through 9 to change the next itemon the line until the desired settings are displayed.

11. Press Select to save after all settings have beenselected. Settings will stop flashing.

12. If thegenerator set is connected toaKohlerrModelRXT transfer switch, the exercise can be changedto a loaded exercise. Set the Exercise Mode toUnloaded Cycle, Unloaded Full, or Loaded Full(RXT ATS required) as shown in Figure 3-8.Unloaded Cycle is recommended. See Sections2.4.2 through 2.4.4 for information about theexercise modes.

13. Set the exercise frequency (weekly or every twoweeks). Weekly exercises are recommended.

14. Press the down arrow button to step to the Returnmenu. Press the Select button to return to themainmenu.

After a scheduled exercise run, the next exercise timeand date will be updated automatically based on theExercise Frequency setting.

Other transfer switches: For a loaded exercise with atransfer switch other than a Kohlerr Model RXT ATS,refer to the transfer switch operation manual forinstructions.

Exerciser Reset

To reset the exerciser to run at a different day and/ortime or to change the exercise mode, follow theprocedure in Section 3.6.2 to change the exercisersettings.


tp6804

System Freq:

XX.X Hz

Genset ---->

System

System Volt

Battery V:

HOLD:

Next Exercise

HR:MN PM MM/DD/YY

HOLD:

Exercise Freq:

Weekly/Bi-Weekly

System Phase

Language:

<---- Return

Next Exercise *

HR:MN PM MM/DD/YY

Exercise Freq:

Weekly

Exercise Mode:

Loaded

HOLD:

Exercise Mode:

Unloaded Cycle/UnloadedFull/ Loaded Full

Contrast:

50

* If the exerciser has not been set, No Exercise Sch will be displayed.

Figure 3-8 Procedure to Set the Exerciser on the RDC2 Controller


3.7 RDC2 Controller MenusController menus display power system information,including status information for the engine, generator,and optional RBUS accessories, exercise settings, andevent history. Some menus allow changes to thecontroller settings. Status information, including theengine runtime, cannot be changed by the operator.

Diagrams in the followingsectionsshowhow tonavigatethrough the menus.


If a setting on the controller display is flashing, editmodehasbeenenabled.Press theOFForAUTObutton toexitthe edit mode.

3.8 Main MenuPress theSelect button once to bring up themainmenu.Overview is displayed. See Figure 3-9. Press the downarrow button to step to the next menu, EngineMetering.Use the UP and DOWN arrow buttons to step up anddown through the menus shown in Figure 3-9.

The controller will exit the main menu after 5 minutes ifno buttons are pressed. To exit the main menuimmediately, press the controller’s OFF or AUTObutton.

Overview ---->1.2 h

Engine ---->Metering

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Generator---->Metering

Genset ---->Information

Genset ---->Run Time

Date ---->and Time

ATS ---->Configuration *

Genset ---->System

Event Log---->

Load ---->Control ]

PIM ---->Status [

Network ---->Information

StatusDisplays

ATS ---->Status

* ATS Configuration appears only if a Model RXT transfer switch is connected.[ PIM Status appears only if a programmable interface module is connected.] Load Control appears only if a load control module (LCM) or load shed kit is connected.

Press the Up and Down arrow buttonsto move between menus.Press OFF or AUTO to exit the menus.

Figure 3-9 RDC2 Main Menu


3.9 Overview Menu

Overview ---->1.2 h

Active Alert(if any)

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Genset StatusStandby



Battery12.3V



Next Exercise:09:00p 09Dec2011

Next Maintenance:150 h or Mar2012

SW Version:12.34

<---- Return

Note: Actual settings may vary.

Figure 3-10 Overview Menu

3.10 Engine Metering MenuThe engine metering menu displays engine statusinformation as shown in Figure 3-11. This menudisplays status information only. No settings can bechanged from this menu.

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Eng Speed:3600 RPM

Battery:12.3 V

<---- Return

Engine ---->Metering

Oil Pressure:Switch: Normal

Oil Temp:123 F


Figure 3-11 Engine Metering Menu


3.11 Generator Metering MenuThe generator metering menu displays the generatorvoltage and frequency. See Figure 3-12.

Voltage Calibration



DANGER

The voltage calibration mode can be entered from theGeneratorMeteringmenu.Contact a Kohler-authorizeddistributor/dealer for service.

The Reset Calibration menu allows you to set thevoltage reading back to the original value aftercalibration, if necessary. See Figure 3-12.

Volts L1--L2:240 V

Volts L2--L3:240 V

Volts L3--L1:240 V

Generator ---->Metering

ResetCalibration

<---- Return

ResetCalib? No

Volts:240 V

Three-phase Single-phase

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ResetCalib? Yes

Frequency:60.0 Hz

Frequency:60.0 Hz


Figure 3-12 Generator Metering Menu


3.12 Generator Set InformationMenu

The generator set model number and serial numbersare displayed. No changes are allowed from this menu.

Model and serial numbers are factory set and should notrequire changes in the field, except in the event that thecontroller is being replaced. A personal computerrunningKohlerSiteTechsoftware is required to enter thegenerator set model number and serial numbers on areplacement controller. Contact an authorized Kohlerdistributor/dealer for service.

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Genset M/N:20RESV

Genset S/N:

Controller S/N:

<---- Return

Genset ---->Information

########

########

Figure 3-13 Generator Set Information Menu

3.13 Genset Run Time MenuThe data shown in Figure 3-14 are displayed. Nochanges are allowed from this menu.

Eng Runtime displays the total number of hours that thegenerator set engine has run. The runtime is notresettable.

The Next Maintenance menu shows the number ofhours of generator set operation until maintenance isrequired. The estimated date for the next scheduledmaintenance is also displayed. The maintenancereminder intervals are based on the enginemanufacturer’s recommendation for changing the oil.Refer to Section 5, Scheduled Maintenance, formaintenance instructions.

After changing the oil and performing otherrecommended maintenance, go to the Overview menuto reset the maintenance timer. See Section 5.2.5 forinstructions to reset the maintenance timer.

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Eng Runtime:

12345.6 h

Eng Starts:

123456

<---- Return

Genset ---->Run Time

Next Maintenance:

150 h or Mar2012

Note: Sample data shown.

Figure 3-14 Generator Set Run Time Menu


3.14 Genset System MenuThe genset system menu displays the systeminformation shown in Figure 3-15. Generator sets arefactorysetandshouldnot require changes to thesystemsettings in the field.

A Kohler authorized distributor or dealer can adjustthese settings, if necessary. If the generator set isreconnected to a different voltage or the systemsettingsrequire adjustment for some other reason, see Section3.5 for instructions to enable editing and change thesystem settings.


Voltage Regulator (VR) Voltage Adj

The generator set voltage is factory set and typicallydoes not require adjustment in the field. If voltageadjustment is required, contact a Kohler authorizeddistributor or dealer for service. Refer to the generatorset Installation Manual for instructions to adjust thevoltage.

Setting the Exerciser

Use the Genset System menus to set the generator setexerciser. Refer to Section 2.4 for instructions to set theexerciser and for more information about exercising thegenerator set.

After a scheduled exercise run, the Next Exercise timeand date will be updated automatically based on theExercise Frequency setting.

Adjusting the Display Contrast

To adjust the display contrast, use the down arrowbutton to step to the Contrast menu. Press the Selectbutton, and then use the up and down arrow buttons toadjust the contrast. Press the Select button to save thecontrast setting.

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Genset ---->

SystemSystem Voltage:

240 V

System Battery:12 V

System Phase:

Single

<---- Return

Next Exercise

06:30p 15Dec2011

Exercise Freq:

Weekly

Exercise Mode:

Unloaded Variable

System Freq:

60 Hz

Meas System:

English

Contrast:

50

VR Voltage Adj:

240.0V


Figure 3-15 Genset System Menu


3.15 ATS Status MenuATS menus appear if a Model RXT transfer switch isconnected to the generator set. If no transfer switch isconnected, or another model ATS is connected to theengine start connections, Remote ATS is displayed onthe ATS Status screen.

The ATS Status menu displays Model RXT transferswitch and source information.

The voltage shown in these menus can be calibrated.Follow the safety precautions at the beginning of thismanuals. Use a voltmeter to measure the line-to-linevoltage and follow the instructions in Figure 3-16 tocalibrate the voltage readings.

Emerg Volts:

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Normal Voltage:L1--L2 240 V

Normal Voltage:L2--L3 240 V

Normal Voltage:L3--L1: 240 V

ATS ---->Status

Normal Freq.:60.0 Hz

ATS Position:Normal

Normal Status:Not/Acceptable

Emerg. Status:Standby

Three-phaseSingle-phase

ResetCalibration

<---- Return

ResetCalib? No

ResetCalib? Yes

Note: If there is no Model RXT transferswitch connected to the generator set,RemoteATS isdisplayedand theotherscreens on this page do not appear.

Normal Freq.:60.0 Hz

Normal Volts:240.0 V

Emerg. Freq.:60.0 Hz

240.0 V

Similar screens appear forthe emergency source.

Normal Rotation:

Note: Sample data shown.

Figure 3-16 ATS Status Menu, with Calibration


3.16 ATS Configuration MenuNote: The ATS Configuration menu appears only if a

Model RXT transfer switch is connected.

Use theATSConfiguration submenu to check theModelRXT transfer switch system settings and time delays,and change the settings, if necessary.

Changing ATS Configuration Settings

To enable editing, press the select button. The valueflashes to indicate that it can be changed. Press the upand down arrow buttons to change the value. Press theSelect button to save the value shown.

Use the up and down arrow buttons to move to the nextvalue to be changed. Repeat the adjustment processuntil all values are correct.

Press the down arrow until Return is displayed. Pressthe select button to return to the main menu.

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Normal Freq:12.3 Hz

<---- Return

Normal Voltage:12345.6 V

ATS ---->Configuration

Emerg. Freq:12.3 Hz

Emerg. Voltage:12345.6 V

Emerg. EngineStart: 3 sec

Transfer FromNormal:3 sec

Transfer FromEmerg.: 120 sec


Figure 3-17 ATS Configuration Menu


3.17 Date and Time MenuThe date and time will typically be set at controllerpower--up. To change the date, time, or time format(12 hour or 24 hour), use the Date and Time menu.See Figure 3-18.

3.18 Networking Information MenusUse the networking menus to view and adjustcommunication settings for systems with remote RBUSdevices such as a PIM or LCM or load shed kit, and forsystems that use the Kohlerr OnCuer Plus GeneratorManagement System.

RBUS is a proprietary RS-485 communicationsprotocol.

The Networking Information menu leads to submenusfor network and RBUS communication settings.

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Date:

02Dec2011

Time:

12:34pm

Time Format:

12hr|24hr

Date andTime

To change the date and time, press the Select buttonSee Figure 3-7 for instructions.

<---- Return

Figure 3-18 Date and Time Menu

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Networking---->Information

Networking---->Status

NS

RBUS ---->Information RB

<---- Return

Networking---->Configuration

NC

See Figure 3-20.

See Figure 3-21.

See Figure 3-22.

Figure 3-19 Networking Information Menu


3.18.1 Networking Status Submenu

The Networking Status submenu contains settings forOnCuerPlus. See the OnCue Plus Software OperationManual for information about the appropriate networksettings for OnCue Plus. Changes to these settings arenot typically required.

If DHCP is enabled, IP parameters are not displayed. IfDHCP is disabled (i.e., if a static IP address is used), theIP parameters are displayed.

To enable or disable DHCP and change the IP settings,go to the Networking Configuration menu. SeeSection 3.18.2.

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IP Address:

123.456.789.123

Gateway:

123.456.789.123

<---- Return

Subnet Mask:

123.456.789.123

DHCP:

Enabled

Ethernet Status:Disconnected

DNS 1:123.456.789.123

DNS 2:

123.456.789.123

OnCue Server:

123.456.789.123

OnCue Status:Connected

Networking---->

Status


Figure 3-20 Network Status Submenu


3.18.2 Networking ConfigurationSubmenu (OnCue Plus Password)

The Networking Configuration menu includes settingsused for communication with the KohlerrOnCuer PlusGenerator Management System.

Password

Note: Use the OnCue password shown on thecontroller display for OnCue Plus applications.

For the initial OnCue Plus setup, you will be required toreset the OnCue password on the RDC2 controller, andthen enter it into the OnCue Plus software. To reset thepassword, follow the instructions in Figure 3-21.

Note: The password is displayed for only 10 seconds.Be sure to write down the password and serialnumber.

A new password is generated each time the resetpassword procedure is performed. If the password is

reset after the OnCue Plus system has been set up, theconnection will be lost. Disconnect the battery power tothe controller, wait a minute, then reconnect power.

DHCP Submenu

For most applications, the Dynamic Host ConfigurationProtocol (DHCP) is enabled and the IP settings cannotbe changed from the controller keypad. If DHCP isenabled, IP parameters are not displayed.

If DHCP is disabled (i.e., if a static IP address isrequired), then the IP parameters can be modified. Forapplications that require static IP addresses, press andhold the select button to enable editing, disable DHCP,and then step to the next parameters and enter theinformation.

If an error occurs while setting a parameter, an errormessage is displayed and then the controller exits theedit mode. Previous settings are preserved.


DNS 2:

123.456.789.123

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<---- Return

DHCP:Enabled

Reset OnCuePassword

Reset OnCuePassword? No

S/N: 1234567New PW: 12345

Press Select to enter YESor NO as displayed. Newpassword is displayed forapproximately 10 seconds.

NetworkingConfiguration

HOLD

Reset OnCuePassword? Yes

UP arrow for YES,Down arrow for NO.



IP Address:

123.456.789.123

Gateway:

123.456.789.123

Subnet Mask:

123.456.789.123

DNS 1:123.456.789.123

DHCP:Disabled

HOLD

UP arrow to enable,Down arrow to disable.

RBUS ---->Information

Figure 3-21 Network Configuration Submenu


3.18.3 RBUS Information

The RBUS Information menu contains settings forremote modules that communicate with the RDC2controller using RBUS protocol. This includes thefollowing optional modules:

D Model RXT transfer switch



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Modules Connected:2

Module Timeouts:1234

Net Cycle Time:123ms

Module Errors:1234

< ---- Return

RDRemote ---->Devices

See Figure 3-23.



RBUS ---->Information

<---- Return

Networking---->Configuration

Figure 3-22 RBUS Information Submenu


3.18.4 Remote Devices Submenu

Check the status of remote devices communicatingthrough RBUS. Device types can include:

D Model RXT ATS



The serial numbers for thePIMand LCMor load shed kitare printed on the circuit boards inside the enclosures.

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Module Status:Connected

Firmware Ver.:122

Module ID:12

S/N: XXXXXXXXX<<*DeviceType*>>

Return ---->

S/N: XXXXXXXXX<<*DeviceType*>>

Comm. Errors:12345

Comm. Timeouts:12345

(Dis)Connected:MM/DD/YY 12:12

<---- Return

Connected: Displays the date and time that thedevice was connected.Disconnected: Displays the last date and time ofsuccessful communication.

Remote ---->Devices

From Figure 3-22:

Figure 3-23 Remote Devices Submenu


3.19 Programmable InterfaceModule (PIM) Status Menu

The PIM status menu displays the status of inputs andoutputs connected to the programmable interfacemodule (PIM). this menu appears only if a PIM isconnected. This is a status displaymenu only. Input andoutput settings cannot be changed from the RDC2controller’s user interface.

A personal computer running Kohlerr SiteTechtsoftware is required to change the input and outputsettings. Contact an authorized distributor or dealer forservice.

TheKohlerrOnCuerPlusManagement Systemcan beused to turn outputs on and off. See the OnCuer PlusSoftware Operation Manual for instructions.

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PIMStatus:

PIM 1 ---->

<---- Return

Input 1In/Active

Output 1:In/Active

Input 2In/Active

Output 2:In/Active

Output 3:In/Active

Output 4:In/Active

Output 5:In/Active

Output 6:In/Active

<---- Return

Figure 3-24 Programmable Interface Module (PIM) Status Menu


3.20 Load Control Module (LCM) orLoad Shed Kit Menus

The Load Control menu displays the status of the LoadControl Module (LCM) or load shed kit inputs andoutputs, and allows a test of the LCM or load shed kitoutput relays. Thismenu appears only if an LCMor loadshed kit is connected.

Generator current is displayed as a percent of themaximum generator capacity. The load control module

or load shed kit adds and sheds loads based on thegenerator current.

The test function cycles the relays in the order of theirpriority. For detailed information about the LCMoperation, refer to TT-1574, provided with the LCM kit.For detailed information about the Load Shed kitoperation, refer to TT--1609, provided with the LoadShed kit.

Input 1:In/Active

Output 1:Add/Shed

Input 2:In/Active

Output 2:Add/Shed

Output 3:Add/Shed

Output 4:Add/Shed

Output 5:Add/Shed

Output 6:Add/Shed

Test OutputsPush Select (blinking)

<---- Return

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Load ---->Control

Load ---->Control 1

<---- Return

GeneratorCurrent: 123 %

Figure 3-25 Load Control Module (LCM) or Load Shed Kit Status Menu


3.21 Event LogThe event log displays up to 1000 controller faults andnotices, starting with the most recent event. Events arenumbered 1--1000, with 1 being the most recent. Eachevent is displayed with the date and time of the event,the number of the event, a code to indicate whether theevent was a warning (W), shutdown (S), orinformational notice ( I), the engine hours at the time ofthe event, and the event description.

The time and date for notices (I) are not stored in thecontroller.

Procedure to View Event History

1. Press Select to enter the main menu.

2. Press thedownarrow to stepdown to theevent log.

3. Press Select to display the most recent event.

4. Press the down arrow to step to the next event.

5. Use the up and down arrow buttons to viewevents.

6. Press the Select button to exit the event log.

To stop viewing the event history before the last event,press the select button to return to the main menu.

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Event Log ---->Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

Press UP and Down arrowbuttons to scroll through events

Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

Press Select button at any time toreturn to the main menu.

Figure 3-26 Event Log


Notes

TP-6880 10/14 53Section 4 DC2 Controller Operation

Section 4 DC2 Controller Operation

4.1 DC2 Generator Set/ TransferSwitch Controller

Model RESVL generator sets are equipped with theDC2 generator set/transfer switch controller.

Model RESV generator sets are equipped with theRDC2 generator set/transfer switch controller. SeeSection 3 for RDC2 controller operation information.

The DC2 controls the following power systemcomponents:

D Model 8RESVL, 10RESVL, or 12RESVL generatorset

D Model RXT Automatic Transfer Switch (ATS)



DC2 controller features include:

D Two-line x 16 character backlit digital display withadjustable contrast

D OFF, AUTO, RUN, and EXERCISE generator setcontrol buttons

4.2 Controls and IndicatorsFigure 4-1 illustrates the DC2 controller. See Figure 4-2for details of the controller’s user interface.

1. User Interface2. USB port (mini-B); see Section 6.2.

1

2

GM77569

Figure 4-1 DC2 Controls and Indicators

1. 2-line LCD display2. EXERCISE button3. RUN button and LED4. OFF button and LED5. AUTO button and LED

1

4 35 2

GM77569

Figure 4-2 DC2 User Interface

TP-6880 10/1454 Section 4 DC2 Controller Operation

4.2.1 Controller Keypad

TheRUN,OFF, andAUTObuttonscontrol thegeneratorset as described in Figure 4-3.

Use the EXERCISE button to set the exerciser on theDC2controller.SeeSection4.5 for instructions to set theexerciser.

Note: A personal computer (laptop) with KohlerrSiteTecht software is required for changingsettings on the DC2 controller.

4.2.2 LED Indicators

LEDs above the RUN, OFF, and AUTO buttons indicatethe mode of operation as shown in Figure 4-4.

Button Button Function

RUN Press to start the generator set. The engine start time delay is ignored.

The software version and engine model are displayed briefly when RUN is pressed.

OFF Stops the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing OFF will stop the crank cycle.

Press to clear faults and reset the controller.

Press and hold to access the event log.

AUTO Press to place the generator set in Automatic (standby) mode.

Press to exit the event log.

Press and hold AUTO and OFF to reset the maintenance timer.

EXERCISE When the controller is in AUTO mode, press to set the exerciser. See Section 4.5.

When the controller is OFF, press and hold to reset the OnCue password. See Section 4.8.

Figure 4-3 DC2 Controller Pushbutton Operation

LED LED Indication Description

RUN RUN LED is on. Generator set is running. Remote start and stop commands are ignored.

OFF OFF LED lights for 2seconds, then flashesevery 2 seconds.

Generator set and controller are off. Remote start/stop commands have noeffect. The exercise cycle will not run.

In Auto mode, OFF LEDflashes quickly to indicatea fault shutdown.

Attention required. Identify and correct the fault condition before resetting thecontroller.

AUTO AUTO LED is on. Automatic (standby) mode. Generator set will respond to engine start andstop commands from the controller (for example, exercise start and stopcommands) or an ATS. Time delays operate as described in Section 2.3.

Figure 4-4 DC2 Controller LED Operation


4.2.3 LCD Display

The controller is equipped with a two-line x 16 characterbacklit digital displaywith adjustable contrast.When thegenerator set is running, the messages shown inFigure 4-5 are displayed. When the system is in AUTO,the LCD display steps through the status messagesshown in Figure 4-6.

When a fault or warning condition exists, the controllerwill show the corresponding message. See Section 2.5for more information on fault and warning messages.

The display backlight turns off after about aminute of noactivity. The backlight turns onwhen a button is pressedor when the generator set starts.

RunningATS: Normal *



Battery 12.3V

Runtime: 12345.6 h

Next Exercise:

7d 6h 42m

Sample data shown.


OnCue Status:

Disconnected [

* Model RXT ATS required[ OnCue status is displayed only if OnCue password hasbeen reset.

Figure 4-5 Status Displays, Generator Running

Genset StateStandby

Battery 12.3V

Runtime: 12345.6 h

Next Exercise:

7d 6h 42m

Sample data shown.


Next Maint:

123h or 12months

OnCue Status:

Disconnected

[ OnCue status is displayed only if OnCue password hasbeen reset.

Figure 4-6 Status Displays, Generator in Standby

4.3 Controller PowerThe DC2 controller is powered by the generator setengine starting battery.

Note: To disconnect controller power, disconnect theutility power to the generator set and disconnectthe battery (negative lead first).

4.4 Battery ChargingThe controller includes a built-in battery charger tomaintain the engine starting battery. The DC2 controllermonitors the battery voltage and provides a constant14±2% VDC voltage and maximum 2.5 amps tocharge the battery.

The installer must connect 120 VAC/60Hz utility powerprovided from thebuildingonabreaker-protectedcircuitfor the built-in battery charger. See the InstallationManual for instructions to connect power.


4.5 ExerciseThe DC2 controller can be set to automatically run thegenerator set at the same time and day each week.Exercising the generator set weekly is required to keepthe engine and alternator in good operating condition.

A laptop computer with Kohlerr SiteTecht softwarecan be used to change the exercise frequency to everytwoweeks. Use aUSB cable to connect the controller tothe computer and see TP-6701, SiteTech OperationManual for instructions.

4.5.1 Exercise Modes

UnloadedCycle or LoadedFull-Speedexercises canbeset from the DC2 controller. The Unloaded Cycleexercise mode is the default exercise mode. A ModelRXT transfer switch is required for the LoadedFull-Speed exercise mode. See Section 2.4 for moreinformation about the exercise modes.

A laptop computer with Kohlerr SiteTecht softwarecan be used to change the exercise mode to UnloadedFull Speed.

4.5.2 Setting the Exerciser

Set the exerciser to automatically run the generator setfor 20 minutes every week. Follow the procedure belowto set the exerciser.

Procedure to Set the Exerciser

1. Press AUTO. Verify that the AUTO LED is on andUtility power is available.

2. Press the exercise button to start an unloadedexercise.

3. If a loaded exercise is required, press the Exercisebutton again within 5 seconds.

4. After 5 seconds, the generator begins its crankcycles. During the crank cycles, the number of thecrank cycle is displayed. No button presses areacknowledged during the crank cycles.

5. The generator runs through the exercise cycledescribed in Section 2.4.2. The controller monitorsthe system during the unloaded exercise asdescribed in System Diagnostics.

6. After 20 minutes, the engine stops automatically.

The exercise time is set to the time the exercise button ispressed. An unloaded or loaded exercise, as selectedabove, will occur at the same time every seven days.

4.5.3 Exerciser Reset

To reset the exerciser to run at a different day and/ortime, follow the procedure in Section 4.5.2 to enter thenew exerciser settings. The old settingswill be replacedby the new time and day.

4.6 Event LogThe event log displays up to 10 controller faults andnotices, starting with the most recent event. Events arenumbered 1--10, with 1 being the most recent. Eachevent is displayed with the date and time of the event,the number of the event, a letter to indicate whether theevent was a warning (W), shutdown (S), orinformational notice ( I), the engine hours at the time ofthe event, and the event description. See Figure 4-7.

tp6804

Any Screen Event number, W/S/I, engine hours

Event name

Press AUTO button at any time to exit the event log.

Hold

OFF

Press OFF

Event number, W/S/I, engine hours

Event name

Figure 4-7 Event Log

Procedure to View Event Log

1. Press the OFF button. The controller must be OFFto display the event log.

2. Press and hold the OFF button until the first eventappears on the display.

3. Press OFF to step through the other events.

4. To exit the Event Log, hold theOFF button or pressthe AUTO button.


4.7 Maintenance TimerThe maintenance timer keeps track of the time until thenext recommended maintenance according to themaintenance schedule for the generator set. Reset themaintenance timer after changing theoil andperformingthe other maintenance tasks recommended inSection 5.

To reset the maintenance timer:

1. Press and hold the OFF and AUTO buttonstogether until Maintenance Timer Reset isdisplayed.

2. Release the OFF and AUTO buttons.

4.8 OnCue Plus PasswordToset theOnCuerPluspasswordon theDC2controller,

1. Press the OFF button and verify that the generatorset is not running.

2. Press and hold the Exercise button until PressAgain to Reset OnCue PW is displayed.

3. Release the Exercise button and press it againwithin 5 seconds.

Note: If the Exercise button is not pressed within 5seconds, the controller exits the passwordreset mode.

4. The genset serial number and newpassword (PW)will be displayed for 10 seconds. Record thepassword for entry into the OnCuer Plus program.


Notes

TP-6880 10/14 59Section 5 Scheduled Maintenance

Section 5 Scheduled Maintenance



WARNING




WARNING

Servicing the alternator. Hot parts can cause severeinjury or death. Avoid touching the alternator field or exciterarmature. When shorted, the alternator field and exciterarmature become hot enough to cause severe burns.

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

Servicing the engine heater. Hot parts can cause minorpersonal injury or property damage. Install the heaterbefore connecting it to power. Operating the heater beforeinstallation can cause burns and component damage.Disconnect power to the heater and allow it to cool beforeservicing the heater or nearby parts.



DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING



WARNING

Servicing the air cleaner. A sudden backfire can causesevere injury or death. Do not operate the generator set withthe air cleaner removed.

Servicing the fuel system. A flash fire can cause severeinjuryor death. Donot smokeor permit flames or sparks nearthe carburetor, fuel line, fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors. Catch fuels in anapproved container when removing the fuel line or carburetor.

TP-6880 10/1460 Section 5 Scheduled Maintenance

The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Useextreme care when handling and storing fuels. Store fuels in awell-ventilated area away from spark-producing equipmentand out of the reach of children. Never add fuel to the tankwhile the engine is running because spilled fuel may ignite oncontact with hot parts or from sparks. Do not smoke or permitflames or sparks to occur near sources of spilled fuel or fuelvapors. Keep the fuel lines and connections tight and in goodcondition. Donot replace flexible fuel lineswith rigid lines. Useflexible sections to avoid fuel line breakage caused byvibration. Do not operate the generator set in the presence offuel leaks, fuel accumulation, or sparks. Repair fuel systemsbefore resuming generator set operation.

Gas fuel leaks. Explosive fuel vapors can cause severeinjury or death. Fuel leakage can cause anexplosion. Checkthe LP vapor gas or natural gas fuel system for leakage byusing a soap and water solution with the fuel system testpressurized to 6--8 ounces per square inch (10--14 incheswater column). Do not use a soap solution containing eitherammonia or chlorine because both prevent bubble formation.A successful test depends on the ability of the solution tobubble.

LP liquidwithdrawal fuel leaks. Explosive fuel vapors cancause severe injury or death. Fuel leakage can cause anexplosion. Check the LP liquid withdrawal gas fuel system forleakage by using a soap and water solution with the fuelsystem test pressurized to at least 90 psi (621 kPa). Do notuse a soap solution containing either ammonia or chlorinebecause both prevent bubble formation. A successful testdepends on the ability of the solution to bubble.

See the Safety Precautions and Instructions at thebeginning of this manual before attempting to service,repair, or operate the generator set. Have anauthorizeddistributor/dealer perform generator set service.

RoutineMaintenance. Refer to the followinggeneratorset service schedule, the engine service schedule, andthe runtime hours displayed on the generator setcontroller to determine when to schedule routinemaintenance. Service the generator set morefrequently if it is subject to extreme weather, longoperating hours, or dusty or dirty conditions.

Maintenance Reminders. The RDC2 and DC2controllersdisplaya remindermessageevery100hoursof engine run time. Change the oil and perform othermaintenance tasks listed on the service schedule. Thenreset the reminder. See Section 5.2.5 for instructions toreset the maintenance reminder.

ServiceSchedule. Performmaintenance on each itemin the service schedule at the designated interval for thelife of the generator set.

Tools. Tools and instruments used to perform somemaintenance items are not generally available to thegenerator set owner. Therefore, have serviceperformed by an authorized distributor/dealer.

5.1 Scheduled MaintenanceRefer to the following service schedules and the runtimehours displayed on the controller display to scheduleroutine maintenance. Intervals are shown in hours ofoperation and/or time intervals (i.e. weekly, monthly,quarterly, etc.) Have an authorized distributor/dealerservice the generator set at the designated intervals inthe service schedule for the life of the generator set.Serviceunits subject to extremeweather, longoperatinghours, or dusty or dirty conditions more frequently.

Contact an authorized distributor/dealer for parts.


5.1.1 Service Schedule

System Component or ProcedureSee

Section

Procedure

FrequencyVisuallyInspect Check Change Clean Test

FuelFlexible lines and connections X R QuarterlyMain tank supply level X WeeklyFuel piping X Yearly

Lubrication 5.2

Oil level X X 8 hours orbefore use

Crankcase breather hose X Yearly or 500 hoursChange oil X Yearly or 100 hoursReplace filter X Yearly or 100 hours

Cooling 5.5

Air ducts, louvers X X Yearly

Exhaust Line 5.6

Leakage X X WeeklyInsulation, fire hazards X YearlyObstructions or combustible materials nearexhaust outlet X Weekly

DC Electrical System 5.7

Battery charger operation, charge rate (ifequipped) X Monthly

Remove corrosion, clean and dry battery and rack X X YearlyClean and tighten battery terminals and inspectboots X X Yearly

Battery electrolyte level and specific gravity * X Yearly

AC Electrical SystemTighten control and power wiring connections X YearlyRemote control system, if equipped X MonthlyVisible wear or damage X QuarterlyWire abrasions where subject to motion X X Six MonthsWire-cable insulation condition X 3 Years or 500 hours

Engine and MountingVisible wear or damage X Weekly

Air cleaner service [ 5.4 150 300 Yearly or hoursshown

Spark plugs (apply anti-seize lubricant for easyremoval)

5.3 X Yearly or 500 hours

Have valve lash checked/adjusted, 8RESV(L) Engine SM D 100 hoursHave valve lash checked/adjusted, 10/12RESV(L) Engine SM D 500 hoursReplace stepper motor coupling and bushing D 500 hours

GeneratorVisible wear or damage X QuarterlyExercise generator set X WeeklyBrushes and collector ring D D Yearly or 300 hoursMeasure and record resistance readings ofwindings with insulation tester (Meggerr, withSCR assembly or rectifier and load leadsdisconnected) *

D 3 Years

General Condition of EquipmentEvidence of vibration, leakage, excessive noise,temperature, or deterioration X X X Weekly

Interior of sound enclosure X X Quarterly* Not necessary for maintenance-free batteries.[ Service more frequently under extremely dusty/dirty conditions.Meggerr is a registered trademark of Biddle Instruments.

X ActionD Authorized distributor/dealer onlyR Replace as necessary


5.2 Lubrication SystemSee the service schedules in Section 5.1 for oil changeand oil filter replacement intervals. See the serviceviews inSection 1.9 for the oil drain, oil check, oil fill, andoil filter locations.

5.2.1 Low Oil Pressure Shutdown

The low oil pressure (LOP) shutdown feature protectsthe engine against internal damage if the oil pressuredrops below a minimum pressure because of oil pumpfailure or other malfunction.

Note: The LOP shutdown feature does not protectagainst damage caused by operating when theoil level is low; it is not a low oil level shutdown.Check the oil level regularly, and add oil asneeded.

5.2.2 Oil Check

The generator set is shipped with oil. Before operatingthe generator set, check the engine oil in the crankcase.

To check the oil level, shut down the generator set andwait several minutes. Remove the dipstick and wipe theend clean, reinsert, and remove. See Figure 5-1.Maintain the oil level between theAdd andFullmarks onthe dipstick. Add 5W-30 synthetic oil when the oil level islow.

Check the oil level before each use. For extendedoperation, check the oil level every 8 hours. Do notcheck the oil level when the generator set is running.

6515

1. Oil dipstick/oil fill2. Oil drain valve

2

1

Figure 5-1 Oil Check (typical)

5.2.3 Engine Oil Recommendation

Use 5W-30 API (American Petroleum Institute) ServiceClass SG, SH, or SJ synthetic oil. Synthetic oil oxidizesand thickens less than other oils and leaves the engineintake valves and pistons cleaner.

5.2.4 Oil Change Procedure



WARNING




WARNING

Servicing the fuel system. A flash fire can cause severeinjuryor death. Donot smokeor permit flames or sparks nearthe carburetor, fuel line, fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors. Catch fuels in anapproved container when removing the fuel line or carburetor.


Note: Dispose of all waste materials (engine oil, fuel,filter, etc.) in an environmentally safe manner.

Note: The oil change procedure requires the use ofrags, a drain tube, and a funnel. Follow theinstructions and use caution to prevent oil fromspilling on or into the alternator.

1. Drain the oil.

a. Press the OFF button on the generator setcontroller.

b. Disconnect the utility power to the generatorset.

c. Disconnect the generator set engine startingbattery, negative (--) lead first.

d. Remove the side panel on the exhaust side ofthe enclosure.

e. Clean the area around the dipstick and oil fillcap.

f. To prevent oil from spilling into the alternator,completely cover the alternator with ragsaround the areas near the oil drain valve and oilfilter.

g. Insert a drain tube (3/8 in. inside diameter) ontothe oil drain valve and place the end of the tubeinto a drain pan. The tube will reduce thepotential for spilled oil.

h. Open the oil drain valve on the engine.

i. Remove the dipstick and oil fill cap. Allow timefor the engine oil to drain completely.

j. Close the oil drain valve and remove the oildrain tube.

k. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter.

b. Loosen the oil filter by rotating itcounterclockwise with an oil filter wrench.

c. As you remove the oil filter, tilt the filter upwardto prevent oil from spilling.

d. Clean the gasket sealing surface of the oil filteradapter.

e. Apply a light coat of clean oil to the rubber sealof the new oil filter.

f. Lightly thread the new oil filter by hand until youfeel Resistance. Then, tighten the filter anadditional 3/4 turn with an oil filter wrench.

3. Fill with oil.

Note: When the oil is drained, some oil remains in theengine. The amount of oil needed to refill theengine may be less than the capacity shown inFigure 5-2. Use the dipstick shown in Figure 5-1to check the oil level during the fill. Do not fill pastthe full mark on the dipstick.

Generator Set Model Oil Capacity, L (qt.)

8RESV/RESVL 1.5 (1.6)

10/12RESV/RESVL 1.9 (2.0)

Figure 5-2 Engine Oil Capacity (new, dry engine)

a. See Section 5.2.3 for the recommended oiltype. To prevent spilling, use a funnel to add oilthrough the oil fill port. Use the dipstick to checkthe oil level before starting to add the final quartof oil. Fill the engine to the F mark on thedipstick.

b. Reinstall the dipstick and the oil fill cap.

c. Remove all rags near the alternator and oildrain valve.

d. Reconnect the generator set engine startingbattery, negative (--) lead last.

e. Reconnect the utility power to the generatorset.

f. Press the RUN button on the generator setcontroller. The generator set will start.

g. Run the generator set for a minute to allow theoil pressure to reach operating range.

h. Stop the generator set, wait 1 minute, and thenrecheck theoil level. Addoil to bring the level upto the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the side panel.

5. Reset the maintenance timer on the controller.


5.2.5 Resetting the Maintenance Timer

Model RESV (RDC2):

1. From theOverviewmenu, step down to theGensetRun Time menu.

2. Press the Select button and then step down to theNext Maintenance screen.

3. Press the Select button.

4. Press the Up arrow button so that “Reset MaintTimer? Yes” is displayed.

5. Press theSelect button.After about twominutes,the new maintenance interval and date aredisplayed.

Model RESVL (DC2):

1. Press and hold the OFF and AUTO buttonstogether until Maintenance Timer Reset isdisplayed.

2. Release the OFF and AUTO buttons.

5.3 Spark Plugs



WARNING


Reset the spark plug gap or replace the plugs with newplugs as necessary.

1. Clean the area around the base of the spark plug tokeep dirt and debris out of the engine.

2. Remove the spark plug and check its condition.Replace the spark plug if it is worn or if its reuse isquestionable.

3. Check the spark plug gap using a wire feelergauge. SeeFigure 5-3 for the recommended sparkplug gap. Adjust the gap by carefully bending theground electrode. See Figure 5-4 and Figure 5-5.

4. For easy removal, applya light coatingof anti-seizelubricant to the cleaned spark plug threads. Wipeaway any excess compound.

5. Reinstall the spark plug into the cylinder head.Torque the spark plug to 24.4--29.8 Nm(18--22 ft. lb.)

Generator Set Model Spark Plug Gap

8/10/12RESV/RESVL 0.508 mm (0.020 in.)

Figure 5-3 Spark Plug Gap

1--514

Figure 5-4 Checking the Spark Plug Gap

1--511

Figure 5-5 Adjusting the Spark Plug Gap


5.4 Air Cleaner Service



WARNING




WARNING

Servicing the air cleaner. A sudden backfire can causesevere injury or death. Do not operate the generator set withthe air cleaner removed.

5.4.1 Air Cleaner, 8RESV/RESVLModels

The engine has a replaceable high-density paper aircleaner element. See Figure 5-6.

Check for a buildup of dirt and debris around the aircleaner system. Keep this area clean. Also check forloose or damaged components. Replace all bent ordamaged air cleaner components.

Note: Operating the engine with loose or damaged aircleaner components could allow unfiltered airinto the engine causing premature wear andfailure.

1

2

3

4 586536

1. Air cleaner base2. Air cleaner element3. Element cover4. Air cleaner knob

Figure 5-6 Air Cleaner Components

Paper Element Service

Use the following procedure to replace the paperelement at the intervals specified in the serviceschedule. Replace the paper element more often underextremely dusty or dirty conditions.

1. Press the OFF button on the generator setcontroller.

2. Disconnect the utility power to the generator set.

3. Disconnect the generator set engine startingbattery, negative (--) lead first.

4. Loosen the cover retaining knobs and remove thecover.

5. Remove the paper element.

Note: Do not wash the paper element or clean itwith pressurized air, as this will damage theelement.

6. Replace the element if it is dirty, bent, or damaged.

7. Check the air cleaner base. Make sure it is secureand not bent or damaged. Also check the elementcover for damage and fit. Replace all damaged aircleaner components. Remove any loose dirt ordebris from the air cleaner base. Wipe the basecarefully so that no dirt drops into the intake throat.Check the condition of the rubber seal on the aircleaner stud and replace the seal if necessary.

8. Reinstall the paper element and the air cleanercover. Secure the cover with the cover retainingknobs.

9. Reconnect the utility power to the generator set.

10. Reconnect the generator set engine startingbattery, negative (--) lead last.


5.4.2 Air Cleaner, 10/12RESV/RESVLModels

The engine is equipped with a replaceable, high densitypaper air cleaner element. See Figure 5-7.

tp6515

1. Air cleaner cover lever2. Air cleaner element3. Base

4. Blower housing5. Air cleaner cover

2

3

1

4

5

Figure 5-7 Air Cleaner Components

Check the air cleaner daily or before starting the engine.Check for a buildup of dirt and debris around the aircleaner system. Keep this area clean. Also check forloose or damaged components. Replace all bent ordamaged air cleaner components.

Note: Operating the engine with loose or damaged aircleaner components could allow unfiltered airinto the engine causing premature wear andfailure.

Paper Element Service

Replace the paper element at the intervals indicated inthe service schedule. See Figure 5-7 for the air cleanercomponents.


2. Disconnect the utility power to the generator set.

3. Disconnect the generator set engine startingbattery, negative (--) lead first.

4. Rotate the air cleaner cover levers outward tounlock cover; remove the air cleaner cover.

5. Remove the paper element from the base.

6. Do not wash the paper element or use pressurizedair, as this will damage the element. Replace adirty, bent, or damaged element. Handle newelements carefully; do not use if the sealingsurfaces are bent or damaged.

7. When servicing the air cleaner, check the aircleaner base. Make sure it is secured and not bentor damaged. Also, check the element cover fordamage or improper fit. Replace all damaged aircleaner components.

Note: If any loose dirt or debris fell on the air cleanerbase when the element was removed, carefullyremove it andwipe thebase clean.Becareful thatnone of it drops into the intake throat.

8. Reinstall the paper element onto the air cleanerbase. Make sure the element is flat and properlyseated.

9. Position the air cleaner cover with levers outwardover air cleaner; turn levers inward to lock.

10. When element replacement is necessary, ordergenuine Kohler parts.

11. Reconnect the power to the battery charger.

12. Reconnect the generator set engine startingbattery, negative (--) lead last.

5.5 Cooling SystemThe engine fan draws cooling air through the openingsin the sides and end near the battery. The alternator fandraws cooling air through openings on the side walls ofthe enclosure. The cooling air mixes with the engineexhaust and is discharged at the exhaust outlet. See theservice view in Section 1.9 for air intake and exhaustlocations. To prevent generator set damage caused byoverheating, keep the housing cooling inlets and outletsclean and unobstructed at all times.

Note: Donot block the generator set cooling air inlets ormount other equipment above them. Overheatingand severe generator damage may occur.

1. Air intake2. Exhaust outlet

1 2

FRONT VIEW

Figure 5-8 Cooling Air Intake and Exhaust


5.6 Exhaust System



WARNING

Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is anodorless, colorless, tasteless, nonirritating gas that can causedeath if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Neveroperate the generator set inside a building. Never operate thegenerator set where exhaust gas could seep inside or bedrawn into a potentially occupied building throughwindows, airintake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbonmonoxide detectors on each level of any building adjacent tothe generator set. Locate the detectors to adequately warn thebuilding’s occupants of the presence of carbon monoxide.Keep the detectors operational at all times. Periodically testand replace the carbon monoxide detectors according to themanufacturer’s instructions.

Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbonmonoxideis a poisonous gas present in exhaust gases. Carbonmonoxide is an odorless, colorless, tasteless, nonirritating gasthat can cause death if inhaled for even a short time. Carbonmonoxide poisoning symptoms include but are not limited tothe following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles


D Stomachache, vomiting, nauseaIf experiencing any of these symptoms and carbon monoxidepoisoning is possible, seek fresh air immediately and remainactive. Do not sit, lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. Seek medicalattention if the condition of affected persons does not improvewithin minutes of breathing fresh air.

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

Remove all combustible materials from the exhaustlocation. Combustible materials include buildingmaterials aswell asnatural surroundings. Keepdry fieldgrass, foliage, and combustible landscaping material aminimum of 1.5 m (5 ft.) from the exhaust outlet.

Periodically inspect the exhaust systemcomponents forcracks, leaks, and corrosion.

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is clear.


5.7 Battery



WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

Battery acid cleanup. Battery acid can cause severeinjury or death. Battery acid is electrically conductive andcorrosive. Add 500 g (1 lb.) of bicarbonate of soda (bakingsoda) to a container with 4 L (1 gal.) of water and mix theneutralizing solution. Pour the neutralizing solution on thespilled battery acid and continue to add the neutralizingsolution to the spilled battery acid until all evidence of achemical reaction (foaming) has ceased. Flush the resultingliquid with water and dry the area.

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injuryor death. Short circuits can cause bodily injury and/orequipment damage. Disconnect the battery before generatorset installation or maintenance. Remove all jewelry beforeservicing the equipment. Use tools with insulated handles.Remove the negative (--) lead first when disconnecting thebattery. Reconnect the negative (--) lead last whenreconnecting the battery. Never connect the negative (--)battery cable to the positive (+) connection terminal of thestarter solenoid. Do not test the battery condition by shortingthe terminals together.

Refer to this section for general battery information andmaintenance. Also consult the battery manufacturer’sinstructions for battery maintenance.

All generator set models use a negative ground with a12-volt engine electrical system. Consult the generatorset nameplate for the engine electrical system voltage.Consult the generator spec sheet for battery capacityrecommendations for replacement purposes. Wiringdiagrams provide battery connection information. SeeFigure 5-9 for typical battery connections.

EZ-273000-J

1 2

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

Figure 5-9 12-Volt Engine Electrical System SingleStarter Motor, Typical Battery Connection

Clean the battery and cables and tighten batteryterminalsusing theserviceschedule recommendations.To prevent corrosion, maintain tight, dry electricalconnections at the battery terminals. To removecorrosion from battery terminals, disconnect the cablesfrom the battery and scrub the terminals with a wirebrush. Clean the battery and cables with a solution ofbaking soda and water. After cleaning, flush the batteryand cables with clean water and wipe them with a dry,lint-free cloth.

After reconnecting the battery cables, coat the batteryterminals with petroleum jelly, silicone grease, or othernonconductive grease.


5.8 Storage ProcedurePerform the following storage procedure beforeremoving the generator set from service for threemonths or longer. Follow the engine manufacturer’srecommendations for storage, if available.

Note: Run the generator set monthly wheneverpossible.

5.8.1 Lubricating System

1. Operate thegenerator set until it reachesoperatingtemperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the enginelubrication oil from the engine crankcase.

4. Refill engine crankcase with oil. See Section 5.2.3for oil recommendations.

5. Run the generator set for a few minutes todistribute the clean oil.

6. Stop the generator set.

5.8.2 Fuel System

1. Start the generator set.

2. With the generator set running, shut off the gassupply.

3. Run the generator set until the engine stops.


5.8.3 Cylinder Lubrication

1. Remove the spark plugs.

2. Pour one tablespoon of engine oil into each sparkplug hole. Install the spark plugs and ground thespark plug leads. Do not connect the leads to theplugs.

3. Crank the engine two or three revolutions tolubricate the cylinders.

5.8.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbentadhesive tape.

3. Mask all areas to be used for electrical contact.

4. Spread a light film of oil over unpainted metallicsurfaces to prevent rust and corrosion.

5.8.5 Battery

Perform battery storage last.


2. Disconnect the battery, negative (--) lead first.

3. Clean the battery.

4. Place the battery in a warm, dry location.

5. Connect the battery to a float/equalize batterycharger, or charge the battery monthly using atrickle charger. Follow the battery chargermanufacturer’s recommendations.


Notes

TP-6880 10/14 71Section 6 Troubleshooting

Section 6 Troubleshooting

6.1 IntroductionUse the troubleshooting charts in this section todiagnose and correct common problems. First check forsimple causes such as a dead engine starting battery,loose connections, or an open circuit breaker. Thecharts include a list of common problems, possiblecauses of the problem, and recommended correctiveactions.

If the procedures in this manual do not explain how tocorrect the problem, contact an authorized Kohlerdistributor/dealer. Maintain a record of repairs andadjustments performed on the equipment. Use therecord to help describe the problem and repairs oradjustments made to equipment.

6.2 USB PortA USB port is located on the front of the controller. SeeFigure 1-2 for location. Use a USB cable with a mini-Bconnector to connect the controller to your personalcomputer (laptop).

Some controller settings can be adjusted using a laptopcomputer with Kohlerr SiteTecht software. SiteTechsoftware is available to Kohler authorized distributorsand dealers. See TP-6701, SiteTecht SoftwareOperation Manual, for more information.

6.3 Fault MessagesThe RDC2/DC2 controller displays fault messages toaid in troubleshooting. Selected fault messages andrecommended checks are listed in Figure 2-3.

Identify and correct the cause of the fault condition.Then reset the controller after a fault shutdown. SeeSection 2.5.4.

6.4 Circuit Protection

If the generator set circuit breaker trips repeatedly,contact an authorized Kohler distributor/ dealer forservice.

6.4.1 Controller Internal CircuitProtection

The controller is equipped with internal circuitprotection. A fault message, Accy PwrOver Warning orMainPwrOverL Shutdown, is displayed if this internalprotection is activated. Press OFF to reset. Contact anauthorized Kohler distributor/ dealer for service.

6.4.2 Line Circuit Breaker

The line circuit breaker interrupts thegenerator output inthe event of a fault in the wiring between the generatorand the load. If the circuit breaker trips, reduce the loadand switch the breaker back to the ON position.

6.4.3 Auxiliary Winding Circuit Breaker

A resettable circuit breaker protects the alternator. Thecircuit breaker is located in the junction box area. SeeFigure 1-2.

TP-6880 10/1472 Section 6 Troubleshooting

6.5 TroubleshootingFigure 6-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connectionsbefore replacing parts.

Problem Possible Cause Corrective Action

Controllerdisplaybacklight is off.

Backlight turns off after about 1 minute with noactivity.

Backlight will turn on when a button is pressed or thegenerator set starts.

Controllerdisplay is off.

Low or no battery voltage. Check connections.Check generator set battery. See Figure 6-1.

The generatorset does notcrank.

Battery weak or dead. Recharge or replace the battery.Battery connections reversed or poor. Check the connections.Fault shutdown. Check the controller display for fault messages. See

Section 2.5. Correct the fault condition and reset thecontroller.

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTOto allow remote starting.

Gererator thermostat tripped. For trips other than temperature (nuisance trips), resetthe thermostat. See Section 2.6.

The generatorset cranks butdoes not start,starts hard,lacks power, oroperateserratically.

Air cleaner clogged. Clean and/or replace the air cleaner.Battery weak or dead. Recharge or replace the battery.Battery connection poor. Clean and tighten the battery connections.Spark plug wire connection loose. Check the spark plug wires.Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if

necessary.

Fuel pressure insufficient. Check the fuel supply and valves.Engine malfunction. Contact an authorized Kohler distributor/dealer.Gererator thermostat tripped. For trips other than temperature (nuisance trips), reset

the thermostat. See Section 2.6.

No AC output. Line circuit breaker in the OFF position. Place the circuit breaker in the ON position.Line circuit breaker tripping because ofoverload.

Reduce the load on the generator set.

Line circuit breaker tripping because of shortcircuit.

Contact an authorized Kohler distributor/dealer forservice.

Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in junction box).Contact an authorized Kohler distributor/dealer forservice if breaker trips repeatedly.

Low output orexcessive dropin voltage.

Generator set overloaded. Reduce the load.

Generator setstops suddenly.

Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil ifnecessary.

Out of fuel. Check fuel supply.Overcrank shutdown. Reset the controller. If the overcrank fault occurs again,

contact an authorized Kohler distributor/dealer.

Auxiliary winding circuit breaker tripped. Reset the circuit breaker (located in junction box.)Contact an authorized Kohler distributor/dealer forservice if breaker trips repeatedly.

Fault shutdown. Check the controller display for fault messages. SeeSection 2.5. Correct the fault condition and reset thecontroller.

Generator set in the OFF mode. Press the RUN button to start the engine or press AUTOto allow remote starting.

Remote stop command received from a remoteswitch, ATS, or OnCuer Plus.

Check the remote switch position. Check OnCue Plus.

Engine malfunction. Contact an authorized Kohler distributor/dealer.

Figure 6-1 General Troubleshooting Chart

TP-6880 10/14 Appendix 73

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupterGND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6880 10/1474 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gasNBS National Bureau of Standards

NC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRBUS RS-485 proprietary

communicationsRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

E 2014 by Kohler Co. All rights reserved.

TP-6880 10/14

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

For the nearest KOHLER authorizedinstallation, service, and sales dealer inthe US and Canada:Call 1-800-544-2444 or visitKOHLERPower.com

Date post:	29-Mar-2018
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