Operation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: VSC TP-6843 12/21d
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. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.
Table of Contents Safety Precautions and Instructions ........................................................................................................................................ 5 Introduction .............................................................................................................................................................................. 11 Service Assistance..............................................................................................................
3.12 3.13 3.14 3.15 Generator Set Information Menu ............................................................................................................................ 38 Genset Run Time Menu ......................................................................................................................................... 39 Genset System Menu ............................................................................................................................................. 39 3.14.
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.
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. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
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. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner.
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. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children.
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. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present.
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. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.
Introduction This manual provides operation and maintenance instructions for the DC (direct current) variable speed model 6VSG generator sets equipped with Kohler VSC generator set controllers. This generator set is approved for use in stationary applications in locations served by a public utility, photovoltaic cells , wind turbines or any combination of power sources tied to a battery bank. Have the generator set installed by an authorized distributor/dealer or service technician.
Nameplate The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from th e nameplate into the spaces provided in the product information section on the inside front cover of this manual. See the service views for the nameplate location. Figure 3 Typical Nameplate Emission Information The Kohler Model CH740 engine used on the 6VSG generator set is certified to operate using natural gas or LPG fuel.
Service Assistance For professional advice and conscientious service, please contact your nearest Kohler distributor or dealer. Visit the Kohler Co. website at KOHLERPower.com. Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. Call toll free in the US and Canada 1-800-544-2444. Outside the US and Canada, call the nearest regional office.
TP-6843 12/21
Section 1. Descriptions and Service Views 1.1 Introduction The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/dealer. 1.
1.5 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.
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.
1.6 Accessories The following optional accessories are offered for the 6VSG generator sets. 1.6.1 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). The carburetor heater prevents condensation and carburetor icing. The heater requires a continuous source of AC power. See the generator set Installation manual for more information. 1.6.
1.7 Service Views 2 7 3 9 10 8 1 12 4 14 11 16 5 12 6 13 17 15 21 18 20 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
2 1 3 4 ComKitB GM85956F 1. 2. 3. 4.
Section 2. Generator Set Operation 2.1 Theory of Operation The generator set utilizes a permanent-magnet alternator to produce 3-phase AC voltage. This voltage is rectified using a fullwave 3-phase rectifier (single block rectifier for 36V and 48V, three individual rectifier blocks for 24V) to produce low -ripple DC output. See Figure 8 and Figure 9.
2.2 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. Check for clean and unobstructed air inlets. Battery. Check for tight battery connections.
2.4.4 Engine Cooldown The engine cooldown time delay allows the engine to run after the loads have been removed. The engine cooldown time delay is set to 5 minutes. The engine stops before the cooldown time delay expires if the temperature drops below the cooled-down temperature level, or if the temperature rises above the high limit during the cooldown cycle. 2.4.
2.5 Exercise The VSC controllers can be set to automatically run the generator set at the same time and day each week. Exercising the generator set weekly or every two weeks is required to keep the engine and alternator in good operating condition. When power is applied to the VSC controller (that is, when the battery is connected), you will be prompted to set the date an d time, and then to set the exerciser. See the VSC Generator Set Controller section for more information.
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. Press the OFF button to reset the controller, or follow the procedure below. See Figure 11. 1.
Warning (W) or Shutdown (SD) Condition Check Engine Oil Pressure Low SD * The LOP switch indicates low oil pressure for more than 5 seconds. Function becomes active 30 seconds after crank disconnect (30 second inhibit). Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in Section 4. Check for leaks in the lubrication system. Check the oil level and add oil if the level is low.
Section 3. VSC Controller Operation 3.1 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: 3.
2-line LCD display Up button AUTO button and LED Select button OFF button and LED Down button RUN button and LED 25% load LED Figure 14 3.2.1 50% load LED 100% load LED 75% load LED KPS_050 GM81498 VSC User Interface Controller Keypad The RUN, OFF, and AUTO buttons control the generator set as described in Figure 15. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.4 for operation instructions.
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. The next LED flashes and stays on for a longer time as the load inc reases. LED LED Operation RUN Lights when the generator set has been started locally by pressing the RUN button.
Active Alert Active Alert Genset Status Running Genset Status Standby Voltage: 54V Load: 73% Battery Engine: 125F Oil Pressure: Okay Engine Runtime: 100.6 h Battery Date: 02DEC2011 Time: HR:MNpm 13.3V Engine Runtime: 100.6 h Next Exercise: 09:00p 09Dec2011 Date: 02DEC2011 Time: HR:MNpm Next Maintenance: 150 h or Mar2012 Generator running Figure 17 3.3 13.3V Automatic mode Sample data shown.
3.5 Changing Settings Some settings can be changed from the controller keypad. The controller settings and generator set outp ut are factory-set and should not require field adjustment under normal circumstances. Check and adjust the settings and/or output when: The controller has been replaced. The voltage requires adjustment for a particular application. Troubleshooting generator set problems.
Changing Date/Time 1. Press the Select button to enter the main menu. Press: 2. Display: Press the down arrow button until the desired menu is displayed. See the figure titled: VSC Main Menu. Date and Time are used for this example. Display: Press: 3. Overview --> 1.2 h Date --> and Time Press the Select button to enter the Date and Time menu. Display: Press: 4. Date 05Dec2011 To change the date and time settings, press the Select button again. The year will flash. Display: Press: 8.
3.6 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. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next.
3.8 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. The controller will exit the main menu after 5 minutes if no buttons are pressed. To exit the main menu immediately, press th e controller’s OFF or AUTO button. Status Displays Overview ---> 1.
3.9 Overview Menu Overview ---> 1.2 h Active Alert (if any) Genset Status Standby Generator: 54V % Load 73% 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.
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. Engine ---> Metering Eng Speed: 2300 R/min Oil Pressure: Switch: OK Oil Temperature: 125 F Battery: 13.
3.11 Generator Metering Menu The generator metering menu displays the generator voltage and % load. See the figure titled: Generator Metering Menu. 3.11.1 Calibration DANGER Hazardous voltage. 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.
3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed (see Figure 23). No changes are allowed from this menu. Model and serial numbers are factory-set and should not require changes in the field, except in the event that the controller is being replaced. A personal computer running Kohler® SiteTech™ software is required to enter the generator set model number and serial numbers on a replacement controller.
3.13 Genset Run Time Menu The data shown in Figure 24 are displayed. No changes are allowed from this menu. The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required. The estimated date for the next scheduled maintenance is also displayed. The maintenance reminder intervals are based on the engine manufacturer’s recommendation for changing the oil. See the Scheduled Maintenance section, for maintenance instructions.
Genset ---> System System Voltage: 54.0V Auto Start Volt: 50V Auto Stop Load: 40% 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.
3.14.1 Adjusting the Display Contrast To adjust the display contrast, use the down arrow button to step to the Contrast menu. Press the Select button, and then use the up and down arrow buttons to adjust the contrast. Press the Select button to save the contrast setting. 3.14.2 System Parameters for Battery Bank Charging The following system parameters can be viewed in the Genset System menu on the user interface on the generator set’s VSC controller.
KPS_104 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. Nominal Voltage Default System Voltage, VDC Figure 28 24V 36V 48V 25 37.5 50 Auto Start Voltage Note: The 3-minute (180-second) time delay can be changed using a personal computer (laptop) and Kohler ® SiteTech™ software.
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 1. Press the AUTO button on the controller. 2. Press the Select button to go to the main menu. See the figure titled: VSC Main Menu. 3. Press the down arrow button to step to the Genset System menu. 4.
Genset System --> System Voltage: 54.0V Auto Start Volt: (V) Auto Stop Load: (%) Load Limit: (%) Fuel Type: Natual Gas HOLD: Next Exercise HR:MN PM MM/DD/YY Next Exercise * HR:MN PM MM/DD/YY HOLD: Exercise Mode: Loaded Exercise Mode: Loaded Full Sp Unloaded Cycle Loaded Full Sp HOLD: Exercise Freq: Weekly Exercise Freq: Weekly/Bi-Weekly Language: English Contrast: 50 <-- Return * If the exerciser has not been set, No Exercise Sch will be displayed.
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: 12:34pm Time Format: 12hr <--- Return To change the date and time, press the Select button. See the figure titled: Changing Settings for instructions.
3.16 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. The Networking Information menu leads to submenus for network and RBUS communication settings. See Figure 32.
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. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed. To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu.
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. If DHCP is disabled (i.e., if a static IP address is required), then the IP parameters can be modified.
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).
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 ---> Devices S/N: XXXXXXXXX <<*DeviceType*>> S/N: XXXXXXXXX <<*DeviceType*>> <---- Return Module Status: Connected Comm. Errors: 12345 Comm. Timeouts: 12345 Module ID: 12 Firmware Ver.
3.17 Programmable Interface Module (PIM) Status Menu Note: The PIM status menu appears if a programmable interface module (PIM) or a communications kit interface board (IB) is connected. The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM) or communications kit interface board (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.
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. See the figure titled: Event Log. 3.18.1 Procedure to View Event History 1.
Section 4. Scheduled Maintenance The prestart checklist in the controller operation manual lists main areas of the generator set that require attention. Some procedures may also require using the generator set service manual or engine service manual. Note: Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.
4.1.1 Service Schedule, 6VSG Models Procedure System Component or Procedure Visually Inspect Check Change Frequency Clean Test Fuel Flexible lines and connections X Main tank supply level (if LPG fueled) R Quarterly X Weekly X X Yearly Oil level X X 8 hrs. or before use Oil level, with oil makeup kit X X 24 hrs.
4.2 Lubrication System See the service schedules section for oil change and oil filter replacement intervals. See the service views section for the oil drain, oil dipstick, oil fill, and oil filter locations. 4.2.1 Low Oil Pressure Shutdown The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction.
4.2.4 Oil Change Procedure Note: Drain the oil while it is still warm. Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. 1. 2. 3. Drain the oil. a. Press the OFF button on the generator set controller. b. Disconnect the AC power to the generator set. c. Disconnect the generator set engine starting battery, negative (–) lead first. d. Open the housing service door and remove roof panel. e. Clean the area around the dipstick and oil fill cap. f.
4.2.5 Resetting the Maintenance Timer 1. In the Overview menu, step down to the Next Maintenance screen. 2. Press the Select button. 3. Press the Up arrow button so that Reset Maint Timer? Yes is displayed. 4. Press the Select button. After about two minutes, the new maintenance interval and date are displayed. 4.3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary. 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
4.4 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. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.
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. 1. Press the OFF button on the generator set controller. 2. Disconnect the AC power to the generator set. 3. Disconnect the generator set engine starting battery, negative (–) lead first. 4. Loosen the cover knob and remove the cover. 5.
4.7 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. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case.
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.
4.8 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 1. Operate the generator set until it reaches operating temperature, or about 15 minutes. 2. Stop the generator set. 3.
Section 5. Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler distributor/dealer.
5.5 Troubleshooting Figure 47 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Recommended Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity. Backlight will turn on when a button is pressed or the generator set starts. Controller display is off. Low or no battery voltage. Check connections. Check generator set battery.
Appendix A. Abbreviations A, amp ampere blk. htr. block heater DAC digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure dB decibel AC alternating current bps bits per second dB(A) decibel (A weighted) A/D ADC analog to digital advanced digital control; analog to digital converter br. BTDC Brass before top dead center DC DCR direct current direct current resistance adj. ADV adjust, adjustment advertising dimensional drawing Btu Btu/min.
FHM flat head machine (screw) in. inch Lpm liters per minute fl. oz. fluid ounce in. H2O inches of water LOP low oil pressure flex. flexible in. Hg inches of mercury LP liquefied petroleum freq. frequency in. Lb. inch pounds LPG liquefied petroleum gas FS full scale Inc. incorporated LS left side ft. foot, feet ind. Industrial Lwa sound power level, A weighted ft. lb. foot pounds (torque) int. internal LWL low water level ft./min. feet per minute int./ext.
N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) NA not available, not applicable pot potentiometer, potential s, sec. second nat. gas natural gas ppm parts per million SI Systeme international d’unites, International System of Units NBS National Bureau of Standards PROM programmable read-only memory SI/EO side in/end out NC normally closed psi pounds per square inch sil.
UHF ultrahigh frequency UIF user interface UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ.
TP-6843 12/21d Original Instructions (English) © 2012 Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.
