Kohler Agregati Upastvo

8/10/2019 Kohler Agregati Upastvo

1/76

Residential/Commercial Generator Sets

Models:

14/20RESA

14/20RESAL

Controllers:

RDC2DC2

TP-6804 2/14e

Operation


2/76

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

WARNING

California Proposition 65

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces

below immediately after unpacking the products so that

the numbers are readily available for future reference.

Record field-installed kit numbers after installing the

kits.

Generator Set Identification NumbersRecord the product identification numbers from the

generator set nameplate(s).

Model Designation

Specification Number

Serial 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 the

engine nameplate.

Manufacturer

Model Designation

Serial Number


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Table of Contents

TP-6804 2/14 Table of Contents

Product Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Descriptions and Service Views 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Engine 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Alternator 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Generator Set Enclosure 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Transfer Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Controllers 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7 Accessories 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.1 Carburetor Heater 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.2 Fuel Regulator Heater 20RESA and RESAL only) 18. . . . . . . . . . . . . . . . . .

1.7.3 OnCue Plus Generator Management System 18. . . . . . . . . . . . . . . . . . . . . .

1.7.4 Programmable Interface Module (PIM) 18. . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.5 Load Control Module (LCM) 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.6 Concrete Mounting Pads 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Service Views 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Generator Set Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Prestart Checklist 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Remote Starting and Stopping 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4 Engine Start Crank Cycle 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5 Engine Cooldown 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.6 Automatic Operation with Model RXT Transfer Switch 22. . . . . . . . . . . . . .

2.3.7 Automatic Operation with Other Transfer Switches 22. . . . . . . . . . . . . . . . .2.4 Exercise 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Setting the Exerciser 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics 23. . . . . . . .

2.4.3 Unloaded Full-Speed Exercise 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4 Loaded Full-Speed Exercise (with RXT only) 24. . . . . . . . . . . . . . . . . . . . . .

2.4.5 Loaded Full-Speed Exercise 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.6 Power Failure During Exercise Cycle 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Faults 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 Warnings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2 Shutdowns 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3 ATS Communication Errors 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4 Resetting the Controller after a Fault Shutdown 25. . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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Table of Contents, continued

TP-6804 2/14Table of Contents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 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) 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 Password 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Scheduled Maintenance 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Scheduled Maintenance 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Service Schedule, 14RESA/RESAL ModelsRESA14 60. . . . . . . . . . . . . . .

5.1.2 Service Schedule, 20RESA/RESAL ModelsRESA20 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 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.6 Oil Cooler 20RESA/RESALRESA20 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Spark Plugs 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Air Cleaner Service 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Air Cleaner, 14RESA/RESALRESA14 64. . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 Air Cleaner, 20RESA/RESAL ModelsRESA20 65. . . . . . . . . . . . . . . . . . . . .

5.5 Cooling System 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Exhaust System 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TP-6804 2/14 Table of Contents

5.7 Battery 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 Storage Procedure 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.1 Lubricating System 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.2 Fuel System 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.3 Cylinder Lubrication 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.4 Exterior Preparation 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8.5 Battery 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Troubleshooting 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Introduction 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Fault Messages 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Circuit Protection 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Controller Internal Circuit Protection 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.2 Line Circuit Breaker 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.3 Auxiliary Winding Circuit Breaker 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Controller Service Access 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Troubleshooting 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TP-6804 2/146

Notes


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TP-6804 2/14 7Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANT SAFETYINSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, or

maintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

This manual hasseveral types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a

hazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severe

personal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that willor can cause minor

personal injuryorproperty damage.

NOTICE

Notice 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 potential

hazards 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 can causesevere injury or death. Battery acidcan cause blindness and burn skin.

Always wear splashproof safety

goggles, 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 aidin thecaseof 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.


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TP-6804 2/148 Safety Precautions and Instructions

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permitflames 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 alljewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetalsurface away fromthe battery. 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. Explosion

can 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 the

battery 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 l ine 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 or

an authorized agency. Train allpersonnel on f ire 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. Carbon

monoxide 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 exhaustfumes when workingon or near the generator set. Neveroperate the generator set inside abuilding. Never operate the generator

set 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 buildingsoccupants of the presence of carbonmonoxide. Keep the detectorsoperational at all times. Periodicallytest and replace the carbon monoxidedetectors according to themanufacturers instructions.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonousgas present inexhaust gases. Carbonmonoxideis 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 does

not improve withinminutes of breathingfresh air.


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TP-6804 2/14 9Safety 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. Neveradd fuel tothe tank while the engine is running

because 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 breakagecaused by vibration. Do notoperate 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 operating

generator 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 is

present. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentandelectrical 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.


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TP-6804 2/1410 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. Hazardous

voltage/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 alljewelry 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 thegenerator 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 setuntilit 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.

Notice

NOTICE

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


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TP-6804 2/14 11Introduction

Introduction

This manual provides operation and maintenanceinstructions for residential/commercial model14/20RESA and 14/20RESAL generator sets equippedwith Kohler RDC2 or DC2 generator set/transfer switchcontrollers. See Figure 1. The RDC2 and DC2controllers control the generator set and the optional

Model RXT transfer switch.

Have the generator set installed by an authorizeddistributor/dealer or service technician. Refer toTP-6803, 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. Read and followtheSafety 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 oftenand perform required service at the prescribedintervals.Obtain service from an authorized service distributor/dealer to keep equipment in top condition.

Figure 1 RESA/RESAL Generator Set

List of Related Literature

Figure 2 identifies literature available for the generatorsets covered in this manual and related accessories.Only trained and qualified personnel should install orservice the generator set.

Generator Set Literature Part Number

Installation Manual, Generator Set TP-6803

Service Manual,

14/20RESA/RESAL Generator Set TP-6805

Transfer Switch Literature

Operation/Installation Manual,

Model RXT Automatic Transfer Switch TP-6807

Operation/Installation Manual,

Model RDT Automatic Transfer Switch TP-6345

Installation Manual,

Model RSB Automatic Transfer Switch TP-6486Operation Manual,

Model RSB Automatic Transfer Switch TP-6487

Accessory Literature

Operation Manual, OnCuerPlus TP-6928

Operation Manual, SiteTechtSoftware TP-6701

Installation Instructions,Load Control Module (LCM) TT-1574

Installation Instructions,Programmable Interface Module (PIM) TT-1584

Figure 2 Related Literature


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TP-6804 2/1412 Introduction

Nameplate

The following illustration shows a typical generator setnameplate. Copy the model, serial, and specificationnumbers from thenameplateinto thespaces provided inthe product information section on the inside front coverof this manual. See the service views in Section 1.8 forthe nameplate location.

GM12070

Emission Information

The Kohlerr Model CH740 engine used on the14RESA/RESAL generator set is certified to operateusing natural gas or propane fuel.

The Kohlerr Model CH1000 engine used on the20RESA/RESAL generator set is certified to operateusing natural gas or propane fuel for emergencystandby use only. This generator set is certified by theU.S. EPA foremergency standby operationbacking up areliable utility source. Operation outside theseguidelines is a violation of national EPA regulations.

The Emission Compliance Period referred to on theEmission Control or AirIndexlabelindicates thenumberof operating hours for which the engine has been shownto meet 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 Moderate

125 hoursIntermediate

250 hoursExtended500 hours

Figure 3 Emission Compliance Period

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH740engines (14RESA/RESAL) is EM for U.S. EPA,California, and Europe.

The exhaust emission control system for the CH1000engine (20RESA/RESAL) is EM for U.S. EPA,California, and Europe.

Generator Set Application

Kohlerr Power Systems (KPS) ensures that all Kohlerrgenerator sets are certified to applicable standards fortheir intended application. It is the owner/operatorsresponsibility 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 for

maintenance/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 sets

certification.

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.


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TP-6804 2/14 13Service Assistance

Service Assistance

For professional advice on generator set powerrequirements and conscientious service, please contactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGeneratorsElectric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat thelabels andstickerson your Kohlerproductor review the appropriate literature or documentsincluded with the product.

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

D Outside the US and Canada,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 Pacific

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

China

North 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 Lanka

India Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

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

Japan, Korea

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

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


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TP-6804 2/1414 Service Assistance

Notes


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TP-6804 2/14 15Section 1 Descriptions and Service Views

Section 1 Descriptions and Service Views

1.1 Introduction

The generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegeneratorsetservicemanual,engineoperationmanual,

and engine service manual for additional specifications.Obtain copies of the latest spec sheets, manuals,diagrams, and drawings from your local distributor/dealer.

1.2 Engine

The generator set has a four-cycle, twin cylinder, air-cooled Kohlerrengine. The engine operates on clean-burning natural gas or LPG. Engine features include:

D Efficient overhead valve design and full pressure

lubrication 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 from natural gasto LPG(and vice- versa)while maintaining emissions certification.

D Digital spark advance optimizes ignition timing fortheselected fuel.

1.3 Alternator

The generator uses Kohlers unique PowerBoosttvoltage regulation system, which provides instantresponse to load changes.

ensures reliable motor starting and consistent voltagelevels. PowerBoostt utilizes a voltage excitationsystem that employs a winding independent of the mainoutput windings to provide excitation voltage.

1.4 Generator Set Enclosure

The generator set is housed in an exclusive engineeredcomposite enclosure that is corrosion-proof, even inharsh seaside environments, and impact-resistant,even in cold weather. The enclosure has a hinged,locking roof that allows easy access to the generator setcontroller when required, but locks securely to preventunauthorized 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 the

tool in a secure location.

1.5 Transfer Switch

The 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,theRDC2andDC2controllerswillnotcontrolthetransfer switch. An ATS other than the Model RXT mustbe equipped with a transfer switch controller and enginestart contacts that connect to the remote engine startterminals on the generator set.

1.6 Controllers

RESA models are equipped with the Residential DigitalControl (RDC2). RESAL models use the Digital Control(DC2). See Figure 1-1.

The controller provides integrated control for thegenerator set, Kohlerr Model RXT transfer switch,

programmable interface module (PIM) and load controlmodule (LCM).

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

RDC2 (RESA) DC2 (RESAL)

Figure 1-1 Controllers


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TP-6804 2/1416 Section 1 Descriptions and Service Views

RDC2 Controller Features

D 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 system

diagnosticsd Unloaded full-speed exercise

d Loaded full-speed exercise (Model RXT ATSrequired)

D Front-access mini USB connector for KohlerrSiteTechtconnection

D Front access mini-breaker protects the alternator

D Integral Ethernet connector for the KohlerrOnCuerPlus Generator Management System

D Built-in 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)

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) menus

d Load status

d Test function


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DC2 Controller Features

D 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 OnCuerstatus (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

D Front access mini-breaker protects the alternator

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)

d Over 70 diagnostic messages can be displayed

D A laptop computer and Kohlerr SiteTech softwarecan be used to change system settings or upgradecontroller firmware.


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1.7 Accessories

The following optional accessories are offered for theRESAand RESAL generator sets.

1.7.1 Carburetor Heater

An optional carburetor heater is recommended forimproved cold starting in locations where the ambient

temperature drops below 0_C (32_F). The carburetorheaterpreventscondensation and carburetor icing. Theheater requires a continuous source of AC power.

See the generator set Installation manual for moreinformation.

1.7.2 Fuel Regulator Heater 20RESAand RESAL only)

An optional fuel regulator heater for the20RESA/20RESAL is recommended for improved coldstarting in locations where the ambient temperaturedrops below --18_C (0_F). The heater requires acontinuous source of AC power.

See the generator set Installation manual for moreinformation.

1.7.3 OnCue Plus GeneratorManagement System

The Kohlerr OnCuer Plus Generator ManagementSystem allows monitoring and control of your generatorset from your home or other location with Internet

access using a computer or mobile device.OnCuerPlus can be configured to send email or textmessage notifications in the event of a generator setfault.

OnCuer versions numbered 1.x are not compatible withthe RDC2 or DC2 controller.

1.7.4 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 RDC2or DC2 controller, and can alsobe controlled remotely using the OnCue program.

ThePIMismountedinaNEMA3Raluminumenclosure,which can be mounted indoors or outdoors. See theinstallation instructions provided with the PIM.

1.7.5 Load Control Module (LCM)

The optional Load Control Module (LCM) provides anautomatic load management system to comply withSection 702.5 of NEC2008. 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 RDC2or DC2 controller.The load on the generator set is monitored, and loadsare added or shed in the order of their priority. Seespecification sheet G6-120 and the LCM installationinstructions for more information.

1.7.6 Concrete Mounting Pads

Kohler offers optional concrete mounting pads that arecustom-designed for Model 14RESA/RESAL and20RESA/RESAL generator sets. Three-inch andfour-inch thick pads are available. Four-inch pads arerecommended for storm-prone areas.


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1.8 Service Views

18

19

2122

1

3

10 11

16, 17

20

ADV-8424

1312

23

1. Hinged inner cover2. Hinged roof3. Air intake4. Lock5. Locking tool, provided with generator set6. Exhaust outlet7. Oil check (dipstick)

8. Oil fill9. Lifting holes

10. Muffler11. Air cleaner12. Oil filter13. Line circuit breaker14. USB connector (for firmware updates)

15. RDC2 or DC2 controller16. Field-connection terminal block (behind panel)17. Digital spark advance ignition (DSAI) leads18. Fuel block (14 kW models) or LPG orifice location (20 kW

models, inside hose fitting)19. Fuel inlet20. Fuel solenoid valve

21. Gas regulator assembly22. AC receptacles for optional carburetor heater (not shown)23. Engine starting battery location (battery purchased separately)24. Oil drain hose25. Nameplate location26. Oil drain valve

24

15

26

14

25

AIR INTAKE SIDE --PANEL

REMOVED TO SHOW DETAIL

6

9

7

8

2

4

5

Figure 1-2 Service View (Model 20RESA shown)


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Notes


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TP-6804 2/14 21Section 2 Generator Set Operation

Section 2 Generator Set Operation

2.1 Prestart Checklist

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 require

verification 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 manufacturers 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 forcorroded or brokenmetalparts 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 or

near, 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 Set

Operate the generator set without load once each weekfor 20 minutes. See Section 2.4 for information aboutloaded and unloaded exercise modes. For instructions

to 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 Operation

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.

See Sections 2.3.6 and 2.3.7 formore information aboutautomatic operation.

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 the

switch 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.


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TP-6804 2/1422 Section 2 Generator Set Operation

Theengine cooldown time delay is set to 5 minutes. 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 the Model RXT is used, anadditional engine cooldown time delay may beprogrammed on the transfer switch. To allow the smartengine cooldown on the RDC2 controller to operatemost efficiently, set the cooldown time on the transferswitch controller to zero or the minimum time allowed.Refer to the instructions provided with the transferswitch for more information.

2.3.6 Automatic Operation with ModelRXT Transfer Switch

The Model RXT transfer switch connects to the RDC2controller through the ATS interface board on thetransfer switch. Also see the Model RXT TransferSwitch Operation/Installation Manual for more

information about transfer switch operation.

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

Automatic Start

The RDC2 controller receives utility source voltagesensing 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.


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2.4 Exercise

The RDC2 or DC2 controller can be set to automaticallyrun the generator set at the same time and day eachweek. Exercising the generator set weekly or every twoweeks is required to keep the engine and alternator ingood 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 the Model 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 provided with 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 electrical

load 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 identifypotentialproblems with thepower output and alert theoperator before an emergency event.

D Ramps down and runs at reduced speed for 5minutestocooldowntheenginebeforeshuttingdownautomatically.

EngineSpeed,

RPM

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 generatorset 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 the


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RDC2/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. Ifthe oilpressureis low, theLow Oil Pressuremessage is displayed and the generator set shutsdown.

2.4.3 Unloaded Full-Speed Exercise

The unloaded full-speedexerciseruns thegeneratorsetat full speed for 20 minutes without 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 transfersthe 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.

Fora 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,theATStransfers to theemergency source, 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.When Utility power is restored,the ATS will re-transfer tothe utility source through normal timing sequences.

2.5 Faults

The RDC2 or DC2 controller displays fault messages forgenerator set warnings and shutdowns. Selected fault

messages 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 set

shuts 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. See

Section 2.5.4 for instructions to reset the controller aftera fault shutdown.

2.5.3 ATS Communication Errors

When a Model 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.


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2.5.4 Resetting the Controller after aFault Shutdown

Always identify and correct the cause of a faultshutdown before resetting the controller. Check thefault message 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 theOFF button to reset thecontroller, or followtheprocedure below. See Figure 2-2.

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

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

6. Press Select. Confirm Clear Fault: NO isdisplayed.

7. Press the Down arrow button. Confirm Clear Fault:YES is displayed.

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

9. Press the Select button to return to the overview

menu. The controller changes to OFF mode.

10. Press AUTO to put thegeneratorset 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


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Fault Message

Warning (W) orShutdown (SD) Condition Check

AC Sens Lost W (1 sec.)

SD (3 sec.) *

AC sensing lost. In Auto mode, generator outputAC sensing is lost. Starts 10 seconds aftercrank 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 currentfault (short circuit) on the accessory controllerpower output.


ATS Com Error 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. I nput to PIM from an

external battery charger (not the built-in batterycharger).

Check external battery charger.

Battery VoltageHigh

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 VoltageLow

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.

Clears when the battery voltage returns to anacceptable level.

Check the battery rating andcondition.

Check the battery charger operation.

Charge or replace the battery.

Engine OilPressure 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 engineoil level regularly as recommended in Section 5.

Check for leaks in the lubricationsystem.

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

EngineSpeedHigh

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


EngineSpeedLow

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.


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Fault

Warning (W) orShutdown (SD) Condition Check

GeneratorFrequency High

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


GeneratorFrequency 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.

Contact an authorized

distributor/dealer for service.

GeneratorVoltageL1-L2High

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


GeneratorVoltageL1-L2Low

SD * Generator voltage low. Output voltage fallsbelow 80% of the nominal system voltage formore than 10 seconds.

Reduce the load and restart thegenerator set.


Lo Crank Vlt W Low cranking voltage. Battery voltage fallsbelow 8 VDC for more than 6 seconds while thestarter is engaged.

Charge or replace the battery.

Locked Rotor SD No engine rotation is sensed during cranking.Shuts down 3 seconds after the fault is detected.

Check the battery.

Check for loose connections.


MainPwrOverLShutdown

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


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.

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

Check for loose connections.


Speed SensorFault

SD Engine speed sensor has failed or enginestalled.


* Engine cooldown runs before shutting down.

Figure 2-3 Controller Fault Messages


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Notes


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TP-6804 2/14 29Section 3 RDC2 Controller Operation

Section 3 RDC2 Controller Operation

3.1 RDC2 Generator Set/Transfer

Switch Controller

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

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

The RDC2 controls the following power systemcomponents:

D Model 14RESA or 20RESA generator set

D Model RXT Automatic Transfer Switch (ATS)

D Load Control Module (LCM)

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 through

menus 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 Indicators

Figure 3-1 illustrates the RDC2 controller. SeeFigure 3-2 for details of the controllers user interface.

1. User Interface; see Figure 3-22. Service access (see Section 6.4)

1

2

GM77569

Figure 3-1 RDC2 Controls and Indicators

9

1. 2-line LCD display2. Up button3. Select button4. Down button

5. 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

68 7

Figure 3-2 RDC2 User Interface


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TP-6804 2/1430 Section 3 RDC2 Controller Operation

3.2.1 Controller Keypad

The RUN, OFF, andAUTObuttons control 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 Model RDT or RSB transfer switch isused.

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


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3.2.3 LCD Display

The controller is equipped with a two-line x 16 characterbacklit digital display withadjustablecontrast. 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 controller

will 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.

tp6804

Genset StatusRunning

Voltage: 240VFreq: 60.0Hz

Engine: 72.0 FOil Pressure: OK

Battery12.3V

Engine Runtime:24.5 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 the Select button, and then use the upand down arrow buttons to adjust the contrast. SeeSection 3.5, Changing Settings, and Section 3.14,Genset System Menu.

Thedisplay backlight turns off after abouta minute of noactivity. The backlightturns on when a button is pressedor when the generator set starts.

tp6804

Battery

12.3V

Engine Runtime:24.5 h

Date: 02DEC2011Time: HR:MNpm

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


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3.3 Controller Power

The 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,

you will 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 and move on to the next. Repeat until allsettingsare saved and the controller returns to the main menu.See Section 3.5 formore detailed instructions to changesettings on theRDC2. See Section 3.6for more detailedinstructions to set the exerciser or change the exercisesettings.

3.4 Battery Charging

The 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 fromthe building on a breaker-protected circuitfor the built-in battery charger.

3.5 Changing Settings

Some settings can be changed from the controllerkeypad. The controller settings and generator setoutput are factory-set and should not require fieldadjustment under normal circumstances. Check andadjust the settings and/or output when:

D The controller has been replaced.

D The voltage requires adjustment for a particularapplication.

D Troubleshooting generator set problems.

Havecontrollersetup and adjustmentperformed onlyby

an authorized 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. Pressthedownarrowbuttonuntilthedesiredmenuis displayed. The Genset System menu 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 the

generator set system settings.

5. To changeany of the gensetsystem settings,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 the Select button to exit themenu.

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

Note:If no buttons are pushed, the controller exits the

menus and returns to the generator set statusdisplay after 5 minutes.


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

2. Press the down arrow button until the desiredmenu is displayed. See Figure 3-9. Date and Timeare used for this example.

3. Press the Select button to enter the Date and Timemenu.

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 the

year.

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 hour

and 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:

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


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3.6 Setting the Exerciser

Set 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, you

will be prompted to set the date andtime, andthento 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 the Select button to enter the Genset 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. IfthegeneratorsetisconnectedtoaKohlerrModelRXT 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 Sections

2.4.2 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 Selectbuttonto return to the mainmenu.

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.


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tp6804

System Freq:

XX.X Hz

Genset ---->

System

System Volt

Battery V:

HOLD:

Next Exercise

HR:M

Documents

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