KOHLER 18RCAL Multi-Fuel LPG-Natural Gas Controller Owner’s Manual

KOHLER 18RCAL Multi-Fuel LPG-Natural Gas Controller

The Kohlerr Advantage

High-Quality Power
Kohler home generators provide advanced voltage and frequency regulation along with ultra-low levels of harmonic distortion for excellent generator power quality to protect your valuable electronics.

Premium 5-yr/2000-hr Limited Warranty Included
Kohler is known for extraordinary reliability and performance. Kohler’s premium limited warranty covers parts, labor, and travel for the full warranty period.

Powerful Performance
Exclusive Powerboostt technology provides excellent starting power.

Aluminum Enclosure

• The attractive aluminum enclosure allows installation as close as 18 inches from your home or small business.
• Enclosure panels can be removed without tools to allow easy access for maintenance and service.

Standard Features

RDC2 Controller

• One digital controller manages both the generator set and transfer switch functions (with optional Model RXT). d Electronic speed control responds quickly to varying demands.
• OnCuer Plus Generator Management System for remote monitoring is included with the generator.

Kohler Command PRO Engine Features

• Kohler Command PROr OHV engine with hydraulic valve lifters for reliable performance without routine valve adjustment or lengthy break-in requirements.

Designed for Easy Installation

• A sturdy aluminum base can be mounted on gravel or a concrete mounting pad.
• Fuel and electrical connections through the enclosure wall eliminate the need for stub-ups through the base.
• The customer connection terminal block located near the controller allows easy access for field wiring.
• Designed for outdoor installation only.

Certifications

• Meets emission regulations for U.S. Environmental Protection Agency (EPA) with both natural gas and LPG. d UL 2200/cUL listed.
• CSA certified.
• Accepted by the Massachusetts Board of Registration of Plumbers and Gas Fitters.
• Meets 181 mph wind rating.
• Approved for stationary standby applications in locations served by a reliable utility source.
• 18RCAL models are packaged with a 200 amp service entrance-rated Model RXT automatic transfer switch with a combined interface/ load management board and corrosion-resistant NEMA 3R aluminum enclosure. See the Model RXT ATS specification sheet for more information.

Warranty

5-year /2000-hour limited warranty for on-grid (standby) applications in locations served by a reliable utility source.

Generator Ratings

Standby Ratings/Line Circuit

Natural Gas/LPG/Breaker

Model| Alt| Voltage| Ph| Hz| kW/kVA| Amps| kW/kVA| Amps| Amps| Poles
---|---|---|---|---|---|---|---|---|---|---
18RCAL| 2F7| 120/240| 1| 60| 18/18| 75| 18/18| 75| 80| 2

Note:
The line circuit breaker is automatically selected based on the generator set model and voltage configuration.

RATINGS:
Standby ratings apply to installations served by a reliable utility source. All single-phase units are rated at 1.0 power factor. The standby rating is applicable to variable loads with an average load factor of 80% for the duration of the power outage. No overload capacity is specified at this rating. Ratings are in accordance with ISO- 3046/1, BS5514, AS2789, and DIN 6271. GENERAL GUIDELINES FOR DERATING:

ALTITUDE:
Derate 4% per 305 m (1000 ft.) elevation above 153 m (500 ft.).

TEMPERATURE:
Derate 2% per 5.5_C(10_F) temperature increase above 16_C(60_F). Availability is subject to change without notice. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler Co. generator dealer for availability.

• Check the appliance manufacturer’s specifications for actual power requirements. Consult a Kohlerr Power Systems professional to calculate your exact residential power system requirements.
• Meets NFPA guidelines for 18-inch clearance to combustible materials. Check state and local codes for the minimum distance required from a structure.

Alternator Specifications

Specifications/Alternator

• Manufacturer Kohler
• Type 2-Pole, Rotating Field

Leads, quantity

• 2F7 4
• Voltage regulator Digital
• Insulation: NEMA MG1-1.66
• Material Class H
• Temperature rise 130_C Standby
• Bearing: quantity, type 1, Sealed
• Coupling Direct
• Amortisseur windings Full
• Voltage regulation, no-load to full-load RMS 1.0%
• One-step load acceptance 100% of Rating
• Peak motor starting kVA: (35% dip for voltages below)
  • 240 V, 1 ph
  • 2F7 (4 lead)
  • 41 (60 Hz)

Alternator Features

• Compliance with NEMA, IEEE, and ANSI standards for temperature rise.
• Self-ventilated and drip-proof construction.
• Windings are vacuum-impregnated with epoxy varnish for dependability and long life.
• Superior voltage waveform and minimum harmonic distortion from skewed alternator construction.
• Digital voltage regulator with +1.0% no-load to full-load RMS regulation.
• Rotating-field alternator with static exciter for excellent load response.
• Total harmonic distortion (THD) from no load to full load with alinearloadis less than 5%.

Application Data

Engine

Engine Specifications

• Manufacturer Kohler
• Engine: model, type CH1000 4-Cycle
• Cylinder arrangement V-2
• Displacement, cm3 (cu. in.) 999 (61)
• Bore and stroke, mm (in.) 90 x 78.5 (3.54 x 3.1)
• Compression ratio 8.8:1
• Main bearings: quantity, type 2, Heavy-Duty Sleeve Bearings
• Rated RPM 3600
• Max. engine power at rated rpm, kW (HP)
  • LPG 23.0 (30.9)
  • Natural gas 20.2 (27.1)
• Cylinder head material Aluminum
• Valve material Steel/Stelliter
• Piston type and material Aluminum Alloy
• Crankshaft material Heat Treated, Ductile Iron
• Governor: type Electronic
• Frequency regulation, no load to full load Isochronous
• Frequency regulation, steady state +0.5%
• Air cleaner type Dry

Engine Electrical

Engine Electrical System

Ignition system/Electronic, Capacitive Discharge

• Starter motor rated voltage (DC) 12
• Battery (purchased separately):
• Ground Negative
• Volts (DC) 12
• Battery quantity 1
• Recommended cold cranking amps:
• (CCA) rating for – 18_C (0_F) 500
• Group size 51

Exhaust

Exhaust System

• Exhaust temperature exiting the enclosure at rated kW, dry, _C (_F) 260 (500)

Lubrication

Lubricating System

• Type Full Pressure
• Oil capacity (with filter), L (qt.) w 1.9 (2.0)
• Oil filter: quantity, type w 1, Cartridge
• Oil cooler Integral

Kohler recommends the use of Kohler Genuine oil and filters.

Fuel Requirements

Fuel System

• Fuel types Natural Gas or LPG
• Fuel supply inlet 1/2 NPT
• Fuel supply pressure, kPa (in. H2O):
  • Natural gas 0.9- 2.7 (3.5-11)
  • LP 1.7- 2.7 (7-11)

Fuel Composition Limits/Nat. Gas/LPG

• Sulfur, ppm mass (maximum) 25 max.
• Lower heating value, MJ/m3 (Btu/ft3), (minimum) 33.2 (890) 84.2 (2260)

Contact your local dealer for suitability and rating derates based on fuel compositions outside these limits.

Fuel Pipe Size| |
---|---|---
Minimum Gas Pipe Size Recommendation, in. NPT| |
Pipe Length,                   Natural Gas| LPG|
m (ft.) 268,000 Btu/hr.       31| 8,000 Btu/hr.|
8   (25)                                              1| 3/4|
15   (50)                                              1| 1|

• 30 (100) 1 1/4 1
• 46 (150) 1 1/4 1 1/4
• 61 (200) 1 1/4 1 1/4

Operation Requirements

| Operation Requirements|
---|---|---
| Fuel Consumption, m 3 /hr. (cfh) @ 60Hz| | |
| % Load                 Natural Gas| | LPG|
| 100                     7.6        (268)| 3.6| | (127)
| 75                      6.2        (219)| 2.9| | (102)
| 50                      4.4        (155)| 2.2| | (78)

• 25 3.5 (123) 1.6 (57)
• Exercise 2 (71) 1 (35)
• Nominal fuel rating: Natural gas: 37 MJ/m3 (1000 Btu/ft.3)
• LPG: 93 MJ/m3 (2500 Btu/ft.3)
• LPG conversion factors:
  • 8.58 ft.3 = 1 lb.
  • 0.535 m3 = 1 kg
  • 36.39 ft.3 = 1 gal.

Generator Set Sound Data

Model 18RCAL 8-point logarithmic average sound levels are 66 dB(A) during weekly engine exercise and 70 dB(A) during full-speed generator diagnostics and normal operation.

All sound levels are measured at 7 meters with no load.

• Lowest of 8 points was measured around the generator. Sound levels at other points around the generator may vary depending on installation parameters.

RDC2 Controller Features

The RDC2 controller provides integrated control for the generator set, Kohlerr Model RXT transfer switch, programmable interface module (PIM), and load shed kit.

Membrane keypad:

• OFF, AUTO, and RUN pushbuttons
• Select and arrow buttons for access to system configuration and adjustment menus
• LED indicators for OFF, AUTO, and RUN modes
• LED indicators for utility power and generator set source availability and ATS position (Model RXT transfer switch required)
• LCD display:
  • Two lines x 16 characters per line
  • Backlit display with adjustable contrast for excellent visibility in all lighting conditions
• Scrolling system status display:
  • Generator set status
  • Voltage and frequency
  • Engine temperature
  • Oil pressure
  • Battery voltage
  • Engine runtime hours
• Date and time displays
• Smart engine cooldown senses engine temperature
• The digital isochronous governor maintains the steady-state speed at all loads
• Digital voltage regulation: 1.0% RMS no-load to full-load D Automatic start with programmed cranking cycle
• The programmable exerciser can be set to start automatically on any future day and time, and run every week or every two weeks
• Exercise modes:
  • Unloaded weekly exercise with complete system diagnostics
  • Unloaded full-speed exercise
  • Loaded full-speed exercise (Model RXT ATS required)
• Front-access mini USB connector for SiteTecht or USB Utility connection
• Integral Ethernet connector for Kohlerr OnCuer Plus
• Built-in 2.5 amp battery charger
• Remote two-wire start/stop capability for optional connection of a Model RDT transfer switch
• Diagnostic messages: Displays diagnostic messages for the engine, generator, Model RXT transfer switch, programmable interface module (PIM), and load management device.
• Maintenance reminders
• System settings:
  • System voltage, frequency, and phase
  • Voltage adjustment
  • The measurement system, English or metric
• ATS status (Model RXT ATS required):
  • Source availability
  • ATS position (normal/utility or emergency/generator)
  • Source voltage and frequency
• ATS control (Model RXT ATS required):
  • Source voltage and frequency settings
  • Engine start time delay
  • Transfer time delays
  • Voltage calibration
  • Fixed pickup and dropout settings
• Programmable Interface Module (PIM) status displays:
  • Input status (active/inactive)
  • Output status (active/inactive)
• Load control menus:
  • Load status
  • Test function

Generator Set Standard Features

• Battery cables
• EPA-certified fuel system
• Aluminum sound enclosure
• Critical silencer
• Field-connection terminal block
• Fuel solenoid valve and secondary regulator
• Line circuit breaker
• The multi-fuel system, LPG/natural gas, field-convertible
• Oil drain extension with shutoff valve
• OnCuer Plus Generator Management System
• Premium 5-year/2000-hour limited standby warranty. Covers parts, labor, and travel for the entire warranty period D RDC2 generator set/ATS controller
• Rodent-resistant construction
• Sound-deadening, flame-retardant foam per UL 94, class HF-1
• 200 amp service entrance-rated Model RXT automatic transfer switch with combined interface/load management board and corrosion-resistant NEMA 3R aluminum enclosure. (Standard with 18RCAL.)

Available Options

Concrete Mounting Pads

• Concrete mounting pad, 3 in. thick
• Concrete mounting pad, 4 in. thick (recommended for storm-prone areas)

Electrical Accessories

• Battery
• Battery heater, 120VAC
• Cold weather package, 120VAC
• Emergency stop kit
• Power Relay Modules (Use up to 4 relay modules with the RXT ATS for load management)
• Programmable interface module (PIM) (provides 2 digital inputs and 6 relay outputs)

Fuel System Accessories

• Flexible fuel line (included on QS models)

• Carburetor heater, 120 VAC
  A carburetor heater is recommended for reliability starting at temperatures below 0_C(32_F ). Do not use cold weather kit. Literature

• General maintenance literature kit

• Overhaul literature kit

• Production literature kit

Maintenance

• Maintenance kit (includes air filter, oil, oil filter, and spark plugs)

Warranty

• 7- Year Limited Warranty
• 10- Year Limited Warranty

Warranties cover parts, labor, and travel for the entire warranty period.

Generator Set Dimensions and Weights

• Generator Set Size, L x W x H:
  • 1193 x 660 x 820 mm (47 x 26.0 x 32.3 in.)

Shipping Weights:

• 18RCA Generator Set: 252 kg (555 lb.)
• 18RCAL with 200 A RXT SE ATS: 272 kg (600 lb.)

NOTE:
Dimensions are provided for reference only and should not be used for planning installation. Contact your local dealer for more detailed information.

2022 Kohler Co. All rights reserved.

KOHLER CO.,

Kohler, Wisconsin 53044 USA
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales and service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com.

References

• Kohler Energy | Cleaner Energy Solutions for individuals, businesses and communities

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