Kohler 6VSG Operation Manual
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Kohler 6VSG Operation Manual

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Operation
DC Generator Sets
Models:
6VSG
24VDC
36VDC
48VDC
Controller:
VSC
TP-6843 12/21d

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Summary of Contents for Kohler 6VSG

  • Page 1 Operation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: TP-6843 12/21d...
  • Page 2 WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Product Identification Information Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................11 Service Assistance................................... 13 Section 1. Descriptions and Service Views ......................15 Introduction ................................15 Engine ..................................15 Generator Set Enclosure ............................15 Alternator ................................15 Controller ................................16 Accessories ................................
  • Page 4 Procedure to View Event History ......................52 Section 4. Scheduled Maintenance ........................53 Scheduled Maintenance ............................53 4.1.1 Service Schedule, 6VSG Models ......................54 Lubrication System ..............................55 4.2.1 Low Oil Pressure Shutdown ........................55 4.2.2 Oil Check ..............................55 4.2.3...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 6 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.
  • Page 7 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
  • Page 8 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.
  • Page 9 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Grounding electrical equipment.
  • Page 10 Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death.

  • Page 11: Introduction

    Refer to Installation Manual, for installation instructions. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
  • Page 12 Emission Information The Kohler Model CH740 engine used on the 6VSG generator set is certified to operate using natural gas or LPG fuel. Refer to the certification label for engine displacement. The exhaust emission control system for the CH740 engines (6VSG) is EPA certified for all 50 states.

  • Page 13: Service Assistance

    (86) 10 6518 7950  Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951  Look at the labels and decals on your Kohler product (86) 10 6518 7952 or review the appropriate literature or documents Fax: (86) 10 6518 7955 included with the product.
  • Page 14 TP-6843 12/21...

  • Page 15: Descriptions And Service Views

    Be sure to close and lock the enclosure, and keep the tool in a secure location. Alternator The 6VSG is a direct current (DC) output machine. It utilizes a 24-pole permanent magnet construction to create high frequency three-phase alternating current which is rectified to produce low-ripple DC output.

  • Page 16: Controller

    Controller The Model 6VSG generator set comes equipped with the VSC controller. See Figure 4. The controller provides integrated control for the generator set and the optional programmable interface module (PIM) or optional communications kit interface board. The controller’s two-line LCD screen displays status messages and system settings that are clear and easy to read in all lighting conditions, including direct sunlight and low light.
  • Page 17 Programmable exerciser can be set to start automatically on any future day and time, and run every week or every two weeks  Three exercise modes  Front-access mini USB connector for SiteTech™ connection  ® Integral Ethernet connector for Kohler® OnCue Plus  Built-in 2.5 amp battery charger  Remote two-wire start/stop capability  Diagnostic messages...

  • Page 18: Accessories

    Oil Makeup Kit The oil makeup kit increases the oil capacity on 6VSG residential/commercial generator sets. The kit includes a 2 qt. (1.9 L) oil reservoir and a large sight gauge for the oil level. The kit is installed inside the enclosure on the 6VSG generator set.

  • Page 19: Service Views

    Service Views ADV-8060 Exhaust air outlet Air cleaner Oil fill Oil drain Oil drain valve Oil filter Muffler Alternator air inlet Customer connection blocks (located behind panel) Electrical inlet access panel Engine starting battery location (battery not included) Lifting hole Controller Engine certification label Load circuit breaker...
  • Page 20 ComKitB GM85956F Interface board (factory-wired to terminal blocks) Intrusion alarm switch Interface board input and output connection terminal blocks Fuel pressure switch Figure 6 Optional Communications Kit Components Oil bottle Engine oil drain valve Valve to sight gauge Valve detail See valve detail Sight gauge GM85224...

  • Page 21: Generator Set Operation

    The voltage is regulated to maintain a constant output voltage, which is equal to the System Voltage setting. When the load o n the 6VSG generator increases, the 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 22: Prestart Checklist

    Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine. Air Inlets.

  • Page 23: Engine Cooldown

    2.4.5 Automatic Operation The 6VSG monitors the voltage of a storage battery bank connected to (+) and (–) of the output block to determine charge condition of the storage battery (see Figure 10). • If the storage battery voltage falls below the minimum voltage for more than 3 minutes, or if a remote start command is rec eived, the generator set starts.

  • Page 24: Exercise

    See the VSC Generator Set Controller section for more information. ® ® An exercise can be started at any time using Kohler OnCue Plus, or can start automatically according to the exercise schedule programmed on the VSC controller.

  • Page 25: Resetting The Controller After A Fault Shutdown

    2.6.3 Resetting the Controller After a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 12 to identify and correct the fault condition before proceeding. Contact an authorized distributor/dealer for service, if necessary.
  • Page 26 Warning (W) or Fault Message Condition Check Shutdown (SD) The LOP switch indicates low oil pressure for more than 5 seconds. Function becomes active 30 seconds after crank Check for leaks in the disconnect (30 second inhibit). Engine Oil lubrication system. SD * Note: Pressure Low...

  • Page 27: Vsc Controller Operation

    Section 3. VSC Controller Operation VSC Generator Set Controller All 6VSG generator sets are equipped with the VSC generator set controller. The VSC controls generator set and the optional Programmable Interface Module (PIM) or Communications Kit. The VSC controller features include: ...

  • Page 28: Controller Keypad

    2-line LCD display Up button AUTO button and LED Select button OFF button and LED Down button RUN button and LED 100% load LED 25% load LED KPS_050 50% load LED 75% load LED GM81498 Figure 14 VSC User Interface 3.2.1 Controller Keypad The RUN, OFF, and AUTO buttons control the generator set as described in Figure 15.

  • Page 29: Led Indicators

    3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 16. Load indication LEDs indicate the load on the generator set. A steadily lighted LED indicates that the load on the generator set is greater than or equal to the level label for that LED.

  • Page 30: Controller Power

    Active Alert Active Alert Genset Status Genset Status Running Standby Voltage: 54V Battery Load: 73% 13.3V Engine: 125F Engine Runtime: Oil Pressure: Okay 100.6 h Battery Date: 02DEC2011 13.3V Time: HR:MNpm Engine Runtime: Next Exercise: 100.6 h 09:00p 09Dec2011 Date: 02DEC2011 Next Maintenance: Time: HR:MNpm 150 h or Mar2012...

  • Page 31: Changing Settings

     Troubleshooting generator set problems. Have controller setup and adjustment performed only by an authorized Kohler distributor/dealer or authorized representative. The following procedure explains how to change settings. See the figure titled: Changing Settings for an example using the Date and Time settings.
  • Page 32 Changing Date/Time Press the Select button to enter the main menu. 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 Press the down arrow button until the desired menu Press the down arrow button to step to the next menu.

  • Page 33: Setting The Exerciser

    Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Controller Power-up When battery power is connected to the controller, you will be prompted to set the date and time, and then to set the exercis er. The first setting will flash.

  • Page 34: Main Menu

    Main Menu Press the Select button once to bring up the main menu. Overview is displayed. See Figure 19. Press the down arrow button to step to the next menu, Engine Metering. Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 19.

  • Page 35: Overview Menu

    Overview Menu Overview ---> Active Alert (if any) 1.2 h Genset Status Standby Generator: 54V % Load Engine: 125F Oil Pressure: OK Battery: 13.3V Engine Runtime: 100.6 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Next Maintenance: 150 h or Mar2012 SW Version: 4.06 <--- Return...

  • Page 36: Engine Metering Menu

    3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 21. This menu displays status information only. No settings can be changed from this menu. Eng Speed: Engine ---> 2300 R/min Metering Oil Pressure: Switch: OK Oil Temperature: 125 F...

  • Page 37: Generator Metering Menu

    Will cause severe injury or death. Disconnect all power sources before opening the enclosure. The calibration mode can be entered from the Generator Metering menu. Contact a 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.

  • Page 38: Generator Set Information Menu

    Model and serial numbers are factory-set and should not require changes in the field, except in the event that the controller is SiteTech™ software is required to enter the generator set model number ® being replaced. A personal computer running Kohler and serial numbers on a replacement controller. Contact an authorized Kohler distributor/dealer for service. Genset M/N: Genset ----> Information...

  • Page 39: Genset Run Time Menu

    A Kohler-authorized distributor or dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see the Changing Settings section for instructions to enable editing and change the system settings.
  • Page 40 Genset ---> System Voltage: System 54.0V Auto Start Volt: Auto Stop Load: Load Limit: 100% Fuel Type: Natural Gas Next Exercise * 1:00PM 02/12/1011 Exercise Mode: Loaded Ful Sp Exercise Freq: Weekly Language: English Contrast: 50 <--- Return * If the exerciser has not been set, No Exercise Sch will be displayed. Figure 25 Genset System Menu TP-6843...

  • Page 41: Adjusting The Display Contrast

    Setting the system voltage to a higher value than the factory default setting will decrease the power output of the generator set. A 6VSG set at the system voltage shown in Figure 26 will have an output of 6 kW. If the system voltage is set to a higher value, the output current decreases.
  • Page 42 Figure 27 Effect of Changing the System Voltage Setting Auto Start Volt: The 6VSG will automatically start when the battery bank voltage has reached or fallen below this value for 180 seconds (3 minutes). Default settings are shown in Figure 28.

  • Page 43: Setting The Exerciser

    3.14.3 Setting the Exerciser This section explains how to change the exercise settings after the initial setup. Follow the procedure below and see the flowchart in Figure 30 to set the exercise time and date, mode, and frequency. Procedure to Set the Exerciser Press the AUTO button on the controller.
  • Page 44 System Voltage: Genset --> 54.0V System 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 Loaded Full Sp Unloaded Cycle Loaded Full Sp HOLD:...

  • Page 45: Date And Time Menu

    3.15 Date and Time Menu The date and time will typically be set at controller powerup. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 31. Date and Time Date: 02Dec2011 Time:...

  • Page 46: Networking Information Menus

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

  • Page 47: Networking Status Submenu

    3.16.1 Networking Status Submenu ® ® The Networking Status submenu contains settings for OnCue Plus. See Figure 33. See the OnCue Plus Software Operation Manual for information about the appropriate network settings. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed.

  • Page 48: Networking Configuration Submenu (Oncue® Password)

    3.16.2 Networking Configuration Submenu (OnCue® Password) ® ® The networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System. See Figure 34. For most applications, DHCP is enabled and the IP settings cannot be changed from the controller keypad. If DHCP is enabled, IP parameters are not displayed.

  • Page 49: 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 35). Networking---> Networking---> Information Status Networking---> Configuration Modules RBUS---> Connected: Information <---- Return Remote ---> Devices See the figure titled: Remote Devices Submenu Net Cycle Time: 123ms...

  • Page 50: Remote Devices Submenu

    3.16.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS (see Figure 36). Device types can include: Programmable Interface Module (PIM) The serial numbers for the PIM are printed on the circuit boards inside the enclosures. From the figure titled: VSC Information Submenu Remote --->...

  • Page 51: Programmable Interface Module (Pim) Status Menu

    (IB). See Figure 37. This is a status display menu only. Input and output settings cannot be changed from the VSC controller’s user interface. SiteTech™ software is required to change the input and output settings for the PIM. ® A personal computer running Kohler Contact an authorized distributor or dealer for service. ® ®...

  • Page 52: 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 of the event, and the event description.

  • Page 53: Scheduled Maintenance

    Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service. Kohler recommends the use of Kohler Genuine oil, filters, and coolant for maintenance and service. WARNING Accidental starting.

  • Page 54: Service Schedule, 6Vsg Models

    Oil level, with oil makeup kit 24 hrs. or before use Crankcase breather hose Yearly or 500 hour Change oil and filter (Kohler PRO 10W-50 oil and 300 hours Kohler PRO filter only) Change oil (conventional oil) Yearly or 100 hours...

  • Page 55: Lubrication System

    The generator set is shipped with Kohler PRO 10W -50 oil. Before operating the generator set, check the engine oil in the crankcase. See Figure 39. Maintain the oil level at or near, not over, the full mark on the dipstick. Add Kohler PRO 10W-50 synthetic oil when the oil level is low. Do not mix conventional and synthetic oils.

  • Page 56: Oil Change Procedure

    Clean the gasket sealing surface of the oil filter adapter. Apply a light coat of clean oil to the rubber seal of the new oil filter. Install the new Kohler PRO extended life oil filter (25 050 53) following the instructions provided with the filter. Fill with oil.

  • Page 57: Resetting The Maintenance Timer

    See Figure 42 and Figure 43. Reinstall the spark plug into the cylinder head. Torque the spark plug to 24.4-29.8 Nm (18-22 ft. lb.) Generator Set Model Spark Plug Gap 6VSG 0.76 mm (0.030 in.) Figure 41 Spark Plug Gap...

  • Page 58: Air Cleaner Service

    Air Cleaner Service The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Figure 44. Cover knob Air cleaner cover Element cover nut Element cover Foam precleaner Air cleaner element Air cleaner base KPS_029 Figure 44 Air Cleaner Components Check for a buildup of dirt and debris around the air cleaner system.

  • Page 59: Cooling System

    Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the pape r element more often under extremely dusty or dirty conditions. Press the OFF button on the generator set controller. Disconnect the AC power to the generator set.

  • Page 60: Engine Starting Battery

    Engine Starting Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
  • Page 61 Utility power for battery charging is connected to the generator set. Before servicing the battery, disconnect the utility power by opening the circuit breaker, which is typically located in the customer's electrical distribution box. Clean the battery and cables and tighten battery terminals using the service schedule recommendations. To prevent corrosion, maintain tight, dry electrical connections at the battery terminals.

  • Page 62: Storage Procedure

    Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available. Note: Run the generator set monthly whenever possible. 4.8.1 Lubricating System Operate the generator set until it reaches operating temperature, or about 15 minutes. Stop the generator set.

  • Page 63: Troubleshooting

    Controller Internal Circuit Protection The controller is equipped with internal circuit protection. A fault message, Accy PwrOver Warning or MainPwrOverL Shutdown, is displayed if this internal protection is activated. Press OFF to reset. Contact an authorized Kohler distributor/dealer fo r service. 5.3.2 Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load.

  • Page 64: Troubleshooting

    Line circuit breaker tripping because of overload. Reduce the load on the generator set. No DC output. Line circuit breaker tripping because of short circuit. Contact an authorized Kohler distributor/dealer for service. Rectifier has failed. Verify that the generator is providing AC voltage. Low output or excessive drop in Generator set overloaded.

  • Page 65: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control;...
  • Page 66 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 67 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 68 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...
  • Page 72 TP-6843 12/21d KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2012 Kohler Co. All rights reserved.

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