Kohler 6VSG Installation Instructions Manual
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Kohler 6VSG Installation Instructions Manual

Kohler 6VSG Installation Instructions Manual

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Installation
DC Generator Sets
TP-6842 7/15b
Models:
6VSG
24VDC
36VDC
48VDC
Controller:
VSC

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Summary of Contents for Kohler 6VSG

  • Page 1 Installation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: TP-6842 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 Generator Set Identification Numbers Engine Identification Record the product identification numbers from the Record the product identification information from the generator set nameplate(s).

  • Page 3: Table Of Contents

    1.7.1 Fuel Conversion, 6VSG ....... 14 Electrical Connections ........15 1.8.1...
  • Page 4 Table of Contents Table of Contents TP-6842 7/15...

  • 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: Exhaust System

    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

    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

    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

    Kohler Co. reserves the Startup and Registration right to change this publication and the products represented without notice and without any obligation When the generator set is installed, complete the or liability whatsoever.

  • Page 10: 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 11: Section 1 Installation

    Have the generator set installed by an authorized odorless, colorless, tasteless, nonirritating gas that can Kohler distributor/dealer or authorized representative. cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set.

  • Page 12: Generator Set Inspection

    1.3 Generator Set Inspection 1.4.2 Vibration Isolation The generator set is equipped with neoprene vibration Complete a thorough inspection of the generator set. isolators. Connections between the generator set or Check for the following: its mounting base and any conduits or fuel lines must include flexible sections to prevent breakage and to 1.

  • Page 13: Fuel Supply

    Fuel Consumption, Model Fuel Type % Load /hr. (cfh) 3.3 (116) 2.7 (96) Natural Gas 2.1 (75) 1.8 (62) 6VSG 1.2 (42) 1.0 (35) 0.9 (32) 0.7 (27) Nominal fuel rating: Natural gas:  37 MJ/m (1000 Btu/ft. ) 93 MJ/m (2500 Btu/ft.

  • Page 14: Fuel Conversion

    LP port to the natural gas, plugging the LP port. Explosive fuel vapors. Procedure to convert from LPG to NG, 6VSG Can cause severe injury or death. 1. Press the OFF button on the generator set controller.

  • Page 15: Electrical Connections

    Code (CEC) and applicable local codes. 1.8.1 Grounding KPS_035 1. Fuel regulator The 6VSG has an isolated output, which should be Figure 1-7 Fuel System referenced to ground. This can be accomplished by connecting either the positive or the negative DC 12.

  • Page 16: Electrical Lead Entry

    1.8.2 Electrical Lead Entry 3. Connect ground (GRD) lead corresponding connection points on the terminal Drill or punch holes in the enclosure for the electrical block. See Section 1.8.1, Grounding. conduit in the locations shown in Figure 1-8. 4. Connect utility power leads to the terminal block Figure 1-8 connections labelled Utility.

  • Page 17: Power Supply

    1.8.4 Power Supply connections must comply with applicable state and local codes. Provide AC power for the battery charger (integral to the VSC controller) and optional carburetor heater. See Figure 1-12. Use Belden #9402 or equivalent The power requirements are shown in Figure 1-10. 20 AWG shielded, twisted-pair cable to connect P10-1 The power source must be GFCI protected.

  • Page 18: Pim Input And Output Connections

    Figure 1-16 The default settings for the inputs and outputs are shown in Figure 1-14. To change the input and output ® settings, use a personal computer running Kohler ™ SiteTech software. See TP-6701, SiteTech Software Operation Manual, for instructions.

  • Page 19: Optional Remote Engine Start Connection

    1.8.8 Optional Remote Engine Start remote start switch to terminals 3 and 4 on the terminal Connection block. See Figure 1-17. Route the engine start leads through separate conduit from the AC accessory A remote start switch can be connected to the power leads.

  • Page 20: Engine Starting Battery

    1.9 Engine Starting Battery Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at WARNING any time, particularly when it is charging. Do not dispose of a battery in a fire.

  • Page 21: Engine Starting Battery Installation Procedure

    2. Thermostat 3. Heater If the battery is disconnected for service or replacement, the exercise settings on the VSC Figure 1-19 6VSG Carburetor Heater controller are lost. Set the exerciser after installing and connecting the battery. TP-6842 7/15 Section 1 Installation...

  • Page 22: Oncue® Generator Management System

    Ethernet cable to the cable in the customer connection box. KPS_042 1. Carburetor heater (air cleaner removed to show heater) 2. Carburetor heater power cord Figure 1-21 Figure 1-20 6VSG Carburetor Heater ® 1.10.2 OnCue Generator Management System ® The OnCue...

  • Page 23: Prestart Installation Check

    1.11 Prestart Installation Check 1.12 Set the Exerciser Review the entire installation section. Inspect all wiring Set the exerciser to automatically run the generator set and connections to verify that the generator set is on the desired day and time every week or every two ready for operation.

  • Page 24: Checking Generator Parameters

    Refer to battery manufacturer to correctly set the A 6VSG set at the default system voltage will have an value. This value should not be confused with the output of 6 kW. If the system voltage is set to a higher voltage designation of the battery bank (four 12-volt value, the output current decreases.

  • Page 25: Auto Start Volt

    Figure 1-27 Auto Start/Auto Stop Delay Settings 1.13.3 Auto Stop Load This value is the load level at which the 6VSG will automatically stop. The automatic stop criteria are met when the load has reached or fallen below this value for the specified delay period (standard 3 minutes and only changed using SiteTech).
  • Page 26 Notes Section 1 Installation TP-6842 7/15...

  • Page 27: Section 2 Installation Drawings

    Section 2 Installation Drawings Compare the controller on your generator set with the Figure 2-2 illustrations in Figure 2-1 to determine whether you have the original or revised controller. Then find the correct drawings for your unit in Figure 2-2. Figure 2-1 GM77569 GM89864...
  • Page 28 Figure 2-3 Figure 2-3 Dimension Drawing ADV-8060, Sheet 1 Section 2 Installation Drawings TP-6842 7/15...
  • Page 29 Figure 2-4 Figure 2-4 Dimension Drawing ADV-8060, Sheet 2 TP-6842 7/15 Section 2 Installation Drawings...
  • Page 30 Figure 2-5 Figure 2-5 Dimension Drawing ADV-8060, Sheet 3 Section 2 Installation Drawings TP-6842 7/15...
  • Page 31 Figure 2-6 Figure 2-6 Schematic Diagram, ADV-8460, Sheet 1 TP-6842 7/15 Section 2 Installation Drawings...
  • Page 32 Figure 2-7 Figure 2-7 Schematic Diagram, ADV-8460, Sheet 2 Section 2 Installation Drawings TP-6842 7/15...
  • Page 33 Figure 2-8 Figure 2-8 Point-to-Point Wiring Diagram, GM81321, Sheet 1 TP-6842 7/15 Section 2 Installation Drawings...
  • Page 34 Figure 2-9 Figure 2-9 Point-to-Point Wiring Diagram, GM81321, Sheet 2 Section 2 Installation Drawings TP-6842 7/15...
  • Page 35 Figure 2-10 Schematic Diagram, ADV-8707, Sheet 1 TP-6842 7/15 Section 2 Installation Drawings...
  • Page 36 Figure 2-11 Schematic Diagram, ADV-8707, Sheet 2 Section 2 Installation Drawings TP-6842 7/15...
  • Page 37 Figure 2-12 Point-to-Point Wiring Diagram, GM93380, Sheet 1 TP-6842 7/15 Section 2 Installation Drawings...
  • Page 38 Figure 2-13 Point-to-Point Wiring Diagram, GM93380, Sheet 2 Section 2 Installation Drawings TP-6842 7/15...

  • Page 39: Appendix A Abbreviations

    (2 bytes) Canadian Electrical Code est. estimated KBus Kohler communication protocol cert. certificate, certification, certified E-Stop emergency stop kilogram cubic feet per hour etc. et cetera (and so forth) kg/cm kilograms per square centimeter cubic feet per minute exh.
  • Page 40 kilohertz National Pipe, Straight SPDT single-pole, double-throw kilojoule NPSC National Pipe, Straight-coupling SPST single-pole, single-throw kilometer National Standard taper pipe spec specification kOhm, k kilo-ohm thread per general use specs specification(s) kilopascal NPTF National Pipe, Taper-Fine square kilometers per hour not required, normal relay sq.
  • Page 41 Notes TP-6842 7/15 Appendix...
  • Page 42 Notes Appendix TP-6842 7/15...
  • Page 44 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-6842 7/15b Call 1-800-544-2444 or visit © 2012, 2013, 2015 by Kohler Co. All rights reserved. KOHLERPower.com...

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