Kohler 6VSG Installation Manual
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Kohler 6VSG Installation Manual

Kohler 6VSG Installation Manual

Dc generator sets
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Installation
DC Generator Sets
Models:
6VSG
24VDC
36VDC
48VDC
Controller:
VSC
TP-6842 9/21c

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Summary of Contents for Kohler 6VSG

  • Page 1 Installation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: TP-6842 9/21c...
  • 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................................... 12 Section 1. Installation .............................. 13 Introduction ................................13 Lifting ..................................14 Generator Set Inspection ............................14 Location and Mounting ............................14 1.4.1 Mounting Area ............................14 1.4.2 Vibration Isolation ............................
  • Page 4 TP-6842 9/21...

  • 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 fuel mixer, fuel line, fuel filter, or other potential sources of 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 CAUTION Welding the generator set. Can cause severe electrical equipment damage. Welding on generator set will cause serious damage to engine electronic controls components. Disconnect all engine electronic control connections before welding. Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (–) lead first.
  • Page 10 TP-6842 9/21...

  • Page 11: Introduction

    National Electrical Code (NEC) and local code requirements. Do not install this generator set indoors. 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: 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 13: Installation

    This equipment must be installed and serviced by qualified electrical personnel. Have the generator set installed by an authorized Kohler distributor/dealer or authorized representative. Install the equipment in compliance with the National Electrical Code (NEC) and local codes. For Canadian installations, refer to the Canadian Electrical Code (CEC).

  • Page 14: Lifting

    Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Model Weight, kg (lb.) 6VSG 190 (420) Figure 2 Approximate Weights Approximate generator set weights are shown in Figure 2. Use lifting bars inserted through the holes in the skid to lift the unit.

  • Page 15: Exhaust Requirements

    1.4.3 Exhaust Requirements Figure 3 gives the exhaust temperature at rated load. The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure. Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials. Maintain the clearances shown in the figure titled: Dimension Drawing ADV-8060, Sheet 3.

  • Page 16: Fuel Pipe Size

    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 17: Fuel Conversion

    1.7 Fuel Conversion WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery. Disabling the generator set.
  • Page 18 A trained technician or an authorized distributor/dealer can convert the fuel system. Model 6VSG generator sets built in 2021 or later use the fuel system shown in this section. The fuel system uses a knob that controls a valve on the regulator to select the fuel type. See Figure 7.
  • Page 19 Fuel Selection, Fuel System Press the OFF button on the generator set controller. Disconnect the power to the battery charger. Disconnect the generator set engine starting battery, negative (-) lead first. Turn off the fuel supply. To change the fuel selection: For natural gas (NG), turn the selection knob all the way clockwise.

  • Page 20: Electrical Connections

    1.8.1 Grounding The 6VSG has an isolated output, which should be referenced to ground. This can be accomplished by connecting either the positive or the negative DC output lead to ground. A floating voltage is not recommended in this application.

  • Page 21: Field-Connection Terminal Block

    1.8.3 Field-Connection Terminal Block The generator set is equipped with a field-connection terminal block. Leads have been factory-installed from the junction box to the terminal block for easy field wiring. See the dimension drawings in the Installation Drawings section for the customer field connection terminal block location. See Figure 10 for terminal block details.

  • Page 22: Power Supply

    AC utility power connections Low voltage communication and engine start connections DC load connections KPS_043A Figure 10 Electrical Connections 1.8.4 Power Supply Provide AC power for the battery charger (integral to the VSC controller) and optional carburetor heater. The power requirements are shown in Figure 11.

  • Page 23: Pim Input And Output Connections

    SiteTech™ software. See TP-6701, SiteTech Software Operation Manual, for instructions. ® computer running Kohler ® ® A personal computer running Kohler OnCue Plus software can be used to actively control PIM outputs. See the OnCue Plus Software Operation Manual for instructions. TP-6842...

  • Page 24: Communications Kit Output Connections

    Connection PIM Settings Input 1 None Input 2 None Output 1 (Relay 1) Output 2 (Relay 2) Common Fault Output 3 (Relay 3) Low Battery Voltage (Programmable) Output 4 (Relay 4) Not in Auto (Programmable) Output 5 (Relay 5) Cooldown (Programmable) Output 6 (Relay 6) Normal Source Failure (Programmable) Figure 15...

  • Page 25: Optional Remote Engine Start Connection

    1.8.8 Optional Remote Engine Start Connection A remote start switch can be connected to the generator set. Connect the engine start leads from a remote start switch to terminals 3 and 4 on the terminal block. See Figure 18. Route the engine start leads through separate conduit from the AC accessory power leads.

  • Page 26: Engine Starting Battery

    1.9 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. 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 27: Engine Starting Battery Installation Procedure

    To ground (–) terminal on or near starter motor. To positive (+) terminal on starter solenoid. KPS_030 Figure 19 Typical Battery Connection 1.9.1 Engine Starting Battery Installation Procedure Use the following procedure to install and connect the generator set engine starting battery. Ensure that the starting battery is fully charged before placing the battery in service.

  • Page 28: Generator Set Accessories

    To install the carburetor heater, follow the instructions provided with the kit. Figure 21 shows the installed carburetor heater kit installed for a 6 kW generator set. The heater requires a continuous source of power. Plug the carburetor heater into the 120 VAC receptacle provided. Thermostat Heater Power plug KPS_041 Figure 20 6VSG Carburetor Heater TP-6842 9/21...

  • Page 29: Oncue® Plus Generator Management System

    Carburetor heater power cord Carburetor heater (air cleaner removed to show heater) KPS_042 Figure 21 6VSG Carburetor Heater 1.10.2 OnCue® Plus Generator Management System ® The OnCue Plus Generator Management System allows monitoring and control of your generator set from a personal computer ®...

  • Page 30: Communications Kit

    ® Ethernet cable for optional OnCue Plus connection KPS_043 ® Figure 22 Network Connection for OnCue Plus 1.10.3 Communications Kit The optional communications kit is factory installed. The communications kit includes the following items:  Interface board with factory set inputs and outputs ...

  • Page 31: Set The Exerciser

    1.12 Set the Exerciser Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks. See the generator set Operation Manual for detailed descriptions of the unloaded and loaded exercise operation. When power is applied to the VSC controller (when the battery or the AC power for the battery charger is connected), you will be prompted to set the date and time, and then to set the exerciser.

  • Page 32: Checking Generator Parameters

    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 default system voltage will have an output of 6 kW. If the system voltage is set to a higher value, the output current decreases.

  • Page 33: Auto Start Volt

    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). This load is detected at the generator.
  • Page 34 TP-6842 9/21...

  • Page 35: Installation Drawings

    Section 2. Installation Drawings This section contains dimension drawings, wiring diagrams, and schematics for the enclosed generator set. Figure 29 lists the drawing numbers and page numbers. See the generator set Operation Manual for service views, if necessary. Installation Drawing Description Figure Number Figure Number Page...
  • Page 36 Figure 30 Dimension Drawing ADV-8060, Sheet 1 TP-6842 9/21...
  • Page 37 Figure 31 Dimension Drawing ADV-8060, Sheet 2 TP-6842 9/21...
  • Page 38 Figure 32 Dimension Drawing ADV-8060, Sheet 3 TP-6842 9/21...
  • Page 39 Figure 33 Schematic Diagram, ADV-8707, Sheet 1 TP-6842 9/21...
  • Page 40 Figure 34 Schematic Diagram, ADV-8707, Sheet 2 TP-6842 9/21...
  • Page 41 Figure 35 Point-to-Point Wiring Diagram, GM93380, Sheet 1 TP-6842 9/21...
  • Page 42 Figure 36 Point-to-Point Wiring Diagram, GM93380, Sheet 2 TP-6842 9/21...

  • Page 43: 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 44 (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 45 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 46 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 47 TP-6842 9/21...
  • Page 48 TP-6842 9/21c 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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