Kohler 6VSG Manual
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Kohler 6VSG Manual

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Operation
DC Generator Sets
TP-6843 7/15b
Models:
6VSG
24VDC
36VDC
48VDC
Controller:
VSC

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Summary of Contents for Kohler 6VSG

  • Page 1 Operation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: TP-6843 7/15b...

  • Page 2: Product Identification Information

    California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service Controller Identification parts. Record the product identification numbers in Record the controller description from the generator the spaces below immediately after unpacking the set operation manual, spec sheet, or sales invoice.

  • Page 3: Table Of Contents

    Figure 1-1 Table of Contents Product Identification Information ..........2 Safety Precautions and Instructions.
  • Page 4 4.1.1 Service Schedule, 6VSG Models ..... . . 46 Lubrication System ......... 47 4.2.1...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS Electro-mechanical equipment, including WARNING generator sets, transfer switches, switchgear, and accessories, can cause WARNING bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers Explosion.
  • Page 6 Battery gases. Explosion can Servicing the air cleaner. A sudden Carbon monoxide detectors. cause severe injury death. backfire can cause severe injury or Carbon monoxide can cause severe Battery gases can cause an explosion. death. Do not operate the generator nausea, fainting, or death.
  • Page 7 Fuel System Hazardous Noise WARNING WARNING CAUTION Hazardous voltage. Backfeed to the utility system can cause property damage, severe Explosive fuel vapors. Hazardous noise. injury, or death. Can cause severe injury or death. Can cause hearing loss. If the generator set is used for Use extreme care when handling, Never operate the generator set standby power, install an automatic...
  • Page 8 Hot Parts Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following WARNING steps: (1) Remove the battery cables, negative (–) lead first. (2) Disconnect all engine electronic control module (ECM) connectors.

  • Page 9: Introduction

    ™ TP-6701 Operation Manual, SiteTech Software available at the time of print. Kohler Co. reserves the Installation Instructions, Programmable right to change this publication and the products Interface Module (PIM) TT-1584 represented without notice and without any obligation or liability whatsoever.
  • Page 10 Nameplate Emission Information The following illustration shows a typical generator set The Kohler Model CH740 engine used on the 6VSG nameplate. Copy the model, serial, and specification generator set is certified to operate using natural gas numbers from the nameplate into the spaces provided or LPG fuel.

  • Page 11: Service Assistance

    • Visit the Kohler Power Systems website at Fax: (86) 10 6518 7955 KOHLERPower.com. East China Regional Office, Shanghai • Look at the labels and decals on your Kohler Phone: (86) 21 6288 0500 product or review the appropriate literature or Fax: (86) 21 6288 0550 documents included with the product.
  • Page 12 Notes Service Assistance TP-6843 7/15...

  • Page 13: Section 1 Descriptions And Service Views

    Section 1 Descriptions and Service Views 1.1 Introduction 1.4 Alternator The 6VSG is a direct current (DC) output machine. It The generator set specification sheets provide specific utilizes a 24-pole permanent magnet construction to generator and engine information. Refer to the spec create high frequency three-phase alternating current sheet for data not supplied in this manual.

  • Page 14: Accessories

    ® ® The Kohler OnCue Generator Management System • Three exercise modes allows monitoring and control of your 6VSG generator ™ • Front-access mini USB connector for SiteTech set from a personal computer located in your home or ® connection at other remote locations.

  • Page 15: Service Views

    1.7 Service Views Figure 1-2 kps_002.eps ADV-8060 1. Exhaust air outlet 12. Lifting hole 2. Air cleaner 13. Controller 3. Oil fill 14. Engine certification label 4. Oil drain 15. Load circuit breaker 5. Oil drain valve 16. Oil dipstick 6.
  • Page 16 Figure 1-3 ComKitB GM85956C 1. Interface board (factory-wired to terminal blocks) 2. Intrusion alarm switch 3. Interface board input and output connection terminal blocks 4. Fuel pressure switch Figure 1-3 Optional Communications Kit Components Section 1 Descriptions and Service Views TP-6843 7/15...

  • Page 17: Section 2 Generator Set Operation

    System Voltage setting. Enclosure. Check that all enclosure panels and When the load on the 6VSG generator increases, the internal baffling are in place. generator controller increases the engine speed. The 6VSG series is designed to produce rated voltage at 2300 rpm with no load and at 2900 rpm when supplying full load.

  • Page 18: Exercising The Generator Set

    2 weeks for 20 minutes. See Section 2.5, Exercise. For instructions to set the exerciser, see The 6VSG monitors the voltage of a storage battery Section 3.6. bank connected to (+) and (–) of the output block to determine charge condition of the storage battery (see 2.4 Generator Set Operation...

  • Page 19: Exercise

    The generator set cannot be restarted until the fault ® An exercise can be started at any time using Kohler condition is corrected and the controller is reset. See ® OnCue , or can start automatically according to the Section 2.6.3 for instructions to reset the controller...

  • Page 20: Resetting The Controller After A Fault Shutdown

    2.6.3 Resetting the Controller After a 2. Press Select again. The active fault message is Fault Shutdown displayed. Always identify and correct the cause of a fault 3. Press Select. Confirm Clear Fault: NO is shutdown before resetting the controller. Check the displayed.
  • Page 21 Warning (W) or Fault Message Shutdown (SD) Condition Check Enclosure The enclosure door is open. (Optional Check for evidence of unauthorized Intrusion Alarm communications kit required.) access to the generator set. Close and lock the enclosure door. Engine Oil SD * The LOP switch indicates low oil pressure for Check for leaks in the lubrication Pressure Low...
  • Page 22 Notes Section 2 Generator Set Operation TP-6843 7/15...

  • Page 23: Section 3 Vsc Controller Operation

    3.1 VSC Generator Set Controller 3.2 Control and Indicators Figure 3-1 illustrates the VSC controller. All 6VSG generator sets are equipped with the VSC Figure 3-2 for details of the controller’s user interface. generator set controller. The VSC controls generator set and the optional...

  • Page 24: Controller Keypad

    3.2.1 Controller Keypad 3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons The RUN, OFF, and AUTO buttons control the indicate the mode of operation as shown in Figure 3-4. generator set as described in Figure 3-3. Load indication LEDs indicate the load on the Use the Select, Up arrow, and Down arrow buttons to generator set.

  • Page 25: Lcd Display

    3.2.3 LCD Display The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast The controller is equipped with a two-line x screen. Press the Select button, and then use the up 16-character backlit digital display with adjustable and down arrow buttons to adjust the contrast.

  • Page 26: Controller Power

    • The voltage requires adjustment for a particular application. • Troubleshooting generator set problems. Have controller setup and adjustment performed only authorized Kohler distributor/dealer authorized representative. The following procedure explains how to change settings. See Figure 3-7 for an example using the Date and Time settings.
  • Page 27 Figure 3-7 Changing Date/Time 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview ----> Press: Display: Date: 1.2 h Press: Display: 03Jan2012 2.

  • Page 28: Setting The Exerciser

    3.6 Setting the Exerciser 10. Repeat steps 5 through 9 to change the next item on the line until the desired settings are Set the exerciser to automatically run the generator set displayed. for 20 minutes every week or every two weeks. 11.
  • Page 29 Figure 3-8 Genset ----> System Voltage: System 54.0V Auto Start Volt: (V) Auto Stop Load: (%) Load Limit: (%) Fuel Type: Natual Gas HOLD: Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY HOLD: Exercise Mode: Exercise Mode: Loaded Full Sp Loaded Unloaded Cycle...

  • Page 30: Vsc Controller Menus

    3.7 VSC Controller Menus If a setting on the controller display is flashing, edit mode has been enabled. Press the OFF or AUTO Controller menus display power system information, button to exit the edit mode. including status information for the engine, generator, 3.8 Main Menu and optional RBUS accessories, exercise settings, and event history.

  • Page 31: Overview Menu

    3.9 Overview Menu 3.10 Engine Metering Menu The engine metering menu displays engine status Figure 3-10 information as shown in Figure 3-11. This menu displays status information only. No settings can be Overview ----> Active Alert changed from this menu. 1.2 h (if any) Figure 3-11...

  • Page 32: Generator Metering Menu

    The calibration mode can be entered from the Generator Metering menu. Contact Kohler-authorized distributor/dealer for service. The Reset Calibration menu allows you to set the readings back to the default settings after calibration, if necessary. See Figure 3-12. Figure 3-12 Generator ---->...

  • Page 33: Generator Set Information Menu

    Section Scheduled Maintenance, required to enter the generator set model number and maintenance instructions. serial numbers on a replacement controller. Contact an authorized Kohler distributor/dealer for service. After changing performing other recommended maintenance, go to the Overview menu Figure 3-13 to reset the maintenance timer.

  • Page 34: Genset System Menu

    The following system parameters can be viewed in the A 6VSG set at the system voltage shown in Genset System menu on the user interface on the Figure 3-15 will have an output of 6 kW. If the system generator set’s VSC controller.
  • Page 35 The default slows, and the load on the generator set decreases. setting is 100%, which gives the maximum current The 6VSG will automatically stop when the load has values shown in Figure 3-18. Refer to the battery...

  • Page 36: Setting The Exerciser

    3.14.2 Setting the Exerciser Figure 3-19 Use the Genset System menus to set the generator set exerciser. See Section 2.5 for instructions to set Genset ----> System Voltage: the exerciser and for more information about System 54.0V exercising the generator set. After a scheduled exercise run, the Next Exercise time Auto Start Volt: and date will be updated automatically based on the...

  • Page 37: Date And Time Menu

    Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM, and for systems that Time Format: ® ® use the Kohler OnCue Generator Management 12hr System. RBUS is a proprietary RS-485 communications <----...

  • Page 38: Networking Status Submenu

    3.16.1 Networking Status Submenu If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), The Networking Status submenu contains settings for the IP parameters are displayed. ® ® OnCue .

  • Page 39: Networking Configuration Submenu (Oncue® Password)

    Submenu (OnCue Password) edit mode. Previous settings are preserved. The networking Configuration menu includes settings ® ® used for communication with the Kohler OnCue Password Generator Management System. See Figure 3-24. ® For the initial OnCue setup, you will be required to ®...

  • Page 40: Rbus Information

    3.16.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the VSC controller using RBUS protocol (see Figure 3-24). This includes the following optional modules: Programmable Interface Module (PIM) Figure 3-24 Networking----> Networking----> Information Status Networking---->...

  • Page 41: Remote Devices Submenu

    3.16.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS (see Figure 3-25). Device types can include: Programmable Interface Module (PIM) The serial numbers for the PIM are printed on the circuit boards inside the enclosures. Figure 3-25 From Figure 3-24: Remote ---->...

  • Page 42: Programmable Interface Module (Pim) Status Menu

    ® ™ 3.17 Programmable Interface A personal computer running Kohler SiteTech software is required to change the input and output Module (PIM) Status Menu settings for the PIM. Contact an authorized distributor Note: The status menu appears or dealer for service.

  • Page 43: Event Log

    3.18 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1-1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning (W), shutdown (S), or informational notice (I), the engine hours at the time...
  • Page 44 Notes Section 3 VSC Controller Operation TP-6843 7/15...

  • Page 45: Section 4 Scheduled Maintenance

    Section 4 Scheduled Maintenance WARNING WARNING Accidental starting. Hot engine and exhaust system. Can cause severe injury or death. Can cause severe injury or death. Disconnect the battery cables before Do not work on the generator set working generator set. until it cools.

  • Page 46: Service Schedule, 6Vsg Models

    4.1.1 Service Schedule, 6VSG Models Procedure Visually System Component or Procedure Section Frequency Inspect Check Change Clean Test Fuel Flexible lines and connections Quarterly Main tank supply level (if LPG fueled) Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use...

  • Page 47: Lubrication System

    4.2 Lubrication System 4.2.3 Engine Oil Recommendation Use 5W-30 API (American Petroleum Institute) See the service schedules in Section 4.1 for oil change Service Class SG, SH, or SJ synthetic oil. Synthetic oil and oil filter replacement intervals. See the service oxidizes and thickens less than other oils and leaves views in Section 1.7 for the oil drain, oil dipstick, oil fill, the engine intake valves and pistons cleaner.

  • Page 48: Resetting The Maintenance Timer

    Figure 4-2 Generator Set Model Oil Capacity, L (qt.) 2. Remove the spark plug and check its condition. 6VSG 1.9 (2.0) Replace the spark plug if it is worn or if its reuse Figure 4-2 Engine Oil Capacity is questionable.

  • Page 49: Air Cleaner Service

    4.4 Air Cleaner Service Precleaner Service Use the following procedure to wash and oil the The engine has a replaceable high-density paper air precleaner as indicated in the service schedule. Wash cleaner element with an oiled foam precleaner. See and oil the precleaner more often under extremely Figure 4-6.

  • Page 50: Cooling System

    4.7 Engine Starting Battery 8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any WARNING loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat.

  • Page 51: Storage Procedure

    4.8 Storage Procedure Refer to this section for general battery information maintenance. Also consult battery Perform the following storage procedure before manufacturer’s instructions for battery maintenance. removing the generator set from service for three All generator set models use a negative ground with a months or longer.

  • Page 52: Battery

    4.8.5 Battery Perform battery storage last. 1. Press the OFF button on the generator set controller. 2. Disconnect the battery, negative (–) lead first. 3. Clean the battery. 4. Place the battery in a warm, dry location. 5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger.

  • Page 53: Section 5 Troubleshooting

    See Figure 5-1. Some controller settings distributor/dealer. Maintain a record of repairs and can be adjusted using a laptop computer with Kohler adjustments performed on the equipment. Use the SiteTech software. Use a USB cable with a mini-B record to help describe the problem and repairs or connector to connect the controller to your PC.

  • Page 54: Troubleshooting

    Place the circuit breaker in the ON position. Line circuit breaker tripping because of overload. Reduce the load on the generator set. Line circuit breaker tripping because of short Contact an authorized Kohler distributor/dealer for circuit. service. Rectifier has failed.

  • Page 55: Appendix A Abbreviations

    (2 bytes) ccw. counterclockwise est. estimated KBus Kohler communication protocol Canadian Electrical Code E-Stop emergency stop kilogram cert. certificate, certification, certified etc. et cetera (and so forth) kg/cm kilograms per square centimeter cubic feet per hour exh.
  • Page 56 kilojoule NPSC National Pipe, Straight-coupling SPST single-pole, single-throw kilometer National Standard taper pipe spec specification kOhm, kΩ kilo-ohm thread per general use specs specification(s) kilopascal NPTF National Pipe, Taper-Fine square kilometers per hour not required, normal relay sq. cm square centimeter kilovolt nanosecond sq.
  • Page 57 Notes TP-6843 7/15 Appendix...
  • Page 58 Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: TP-6843 7/15b Call 1-800-544-2444 or visit © 2012, 2013, 2015 by Kohler Co. All rights reserved. KOHLERPower.com...

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