Operation DC Generator Sets Models: 6VSG 24VDC 36VDC 48VDC Controller: VSC TP-6843 1/13a
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 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. Record field-installed kit numbers after installing the kits.
Figure 1-1 Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents 3.14.1 System Parameters for Battery Bank Charging . . . . . . . . . . . . . 3.14.2 Setting the Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14.3 Adjusting the Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . Date and Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Networking Information Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16.1 Networking Status Submenu . . . .
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electro-mechanical 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 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 any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Fuel System ! Hazardous Noise ! WARNING Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion.
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. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.
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 Emission Information The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See the service views in Section 1.7 for the nameplate location. 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 on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. China North China Regional Office, Beijing • Consult the Yellow Pages under the heading Generators—Electric. Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 • Visit the Kohler Power Systems website at KOHLERPower.com.
Notes 12 Service Assistance TP-6843 1/13
Section 1 Descriptions and Service Views 1.1 Introduction 1.4 Alternator 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. The 6VSG is a direct current (DC) output machine.
◦ Backlit display with adjustable contrast for 1.6 Accessories excellent visibility in all lighting conditions The following optional accessories are offered for the 6VSG generator sets. • Scrolling system status display ◦ ◦ ◦ ◦ ◦ ◦ Generator set status 1.6.1 Voltage and percent load 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.
1.7 Service Views Figure 1-2 2 3 8 9 1 10 7 6 4 5 14 11 12 16 15 13 17 21 20 1. Exhaust air outlet 2. Air cleaner 3. Oil fill 4. Oil drain 5. Oil drain valve 6. Oil filter 7. Muffler 8. Alternator air inlet 9. Customer connection blocks (located behind panel) 10. Electrical inlet access panel 11. Engine starting battery location (battery not included) kps_002.eps ADV-8060 19 18 12. Lifting hole 13. Controller 14. Engine certification label 15. Load circuit breaker 16. Oil dipstick 17.
Figure 1-3 2 1 4 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.
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 full-wave 3-phase rectifier (single block rectifier for 36V and 48V, three individual rectifier blocks for 24V) to produce low-ripple DC output. See Figure 2-1 and Figure 2-2.
Exhaust System. Check for exhaust leaks and blockages. Check the muffler condition. • Inspect the exhaust system components for cracks, leaks, and corrosion. Check for tight exhaust system connections. • Check for corroded or broken metal parts and replace them as needed. • Check that the exhaust outlet is unobstructed. Oil Level. Check the oil level before starting the generator set and at the intervals given in Section 4, Scheduled Maintenance.
c. The load limit is returned to 5% for 6 minutes to allow the generator to cool down before stopping. Figure 2-3 1 2 3. Loaded Full Speed Exercise. The generator operates normally. Voltage is regulated to Voltage Regulator Average Voltage Adjustment, and load is regulated to Genset Maximum Percent Capacity. The generator stops after 20 minutes, regardless of the load on the generator. 2.6 Faults The VSC controller displays fault messages for generator set warnings and shutdowns.
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 2-5 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 2-4. 1.
Fault Message Enclosure Intrusion Alarm Engine Oil Pressure Low Warning (W) or Shutdown (SD) W SD * Condition Check The enclosure door is open. (Optional communications kit required.) Check for evidence of unauthorized access to the generator set. Close and lock the enclosure door. 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.
Notes 22 Section 2 Generator Set Operation TP-6843 1/13
Section 3 VSC Controller Operation 3.1 VSC Generator Set Controller 3.2 Control and Indicators All 6VSG generator sets are equipped with the VSC generator set controller. Figure 3-1 illustrates the VSC controller. See Figure 3-2 for details of the controller’s user interface. The VSC controls generator set and the optional Programmable Interface Module (PIM) or Communications Kit.
3.2.1 Controller Keypad 3.2.2 LED Indicators The RUN, OFF, and AUTO buttons control the generator set as described in Figure 3-3. LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-4. 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. Load indication LEDs indicate the load on the generator set.
3.2.3 LCD Display The controller is equipped with a two-line x 16-character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5. The VSC controller measures and displays the average DC output voltage on the auto-scrolling display. When the system is in standby mode and the controller is in AUTO, the screens shown in Figure 3-6 are displayed. The display contrast is adjustable.
3.3 Controller Power The VSC controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the AC power to the generator set starting battery. If controller power is disconnected and reconnected, you will be prompted to set the time, date, and exerciser. 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.
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: 1.2 h Press: 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and Time are used for this example. Date Press: Display: ----> Date: Display: 05Dec2011 4. To change the date and time settings, press the Select button again. The year will flash.
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 exerciser. 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. See Section 3.
Figure 3-8 Genset System ----> System Voltage: 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: Loaded Full Sp Unloaded Cycle Loaded Full Sp Exercise Mode: Loaded HOLD: Exercise Freq: Exercise Freq: Weekly Weekly/Bi-Weekly Language: English Contrast: 50 tp6804 <---- Return * If the exerciser has not been set, No Exercise Sch will be displayed.
3.7 VSC Controller Menus Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. Diagrams in the following sections show how to navigate through the menus. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of the controller settings.
3.9 Overview Menu 3.10 Engine Metering Menu Figure 3-10 Overview ----> 1.2 h Active Alert (if any) The engine metering menu displays engine status information as shown in Figure 3-11. This menu displays status information only. No settings can be changed from this menu. Figure 3-11 Genset Status Standby Generator: 54V % Load 73% Engine: 125F Oil Pressure: OK Engine ----> Metering Eng Speed: 2300 R/min Oil Pressure: Switch: OK Oil Temperature: 125 F Battery: Battery: 13.3 V 13.
3.11 Generator Metering Menu 3.11.1 Calibration The generator metering menu displays the generator voltage and % load. See Figure 3-12. ! DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. 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 3.13 Genset Run Time Menu The generator set model number and serial numbers are displayed (see Figure 3-13). 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.
3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-19. Generator sets are factory-set and should not require changes to the system settings in the field. 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 Section 3.5 for instructions to enable editing and change the system settings.
Figure 3-17 KPS_104 Figure 3-17 Effect of Changing the System Voltage Setting Auto Stop Load: The auto stop load is set as a percentage of full load. As the battery bank approaches the fully charged state, the charge rate slows, and the load on the generator set decreases. The 6VSG will automatically stop when the load has reached or fallen below the Auto Stop Load setting for 180 seconds (3 minutes). The default setting is 40% load.
3.14.2 Setting the Exerciser Use the Genset System menus to set the generator set exerciser. See Section 2.5 for instructions to set the exerciser and for more information about exercising the generator set. After a scheduled exercise run, the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting. Figure 3-19 Genset ----> System Voltage: System 54.0V Auto Start Volt: 50V 3.14.
3.15 Date and Time Menu Figure 3-20 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 3-20. Date and Time Date: 02Dec2011 3.16 Networking Information Menus Time: 12:34pm 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® Generator Management System.
3.16.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue®. See Figure 3-22. See the OnCue® Software Operation Manual for information about the appropriate network settings for OnCue®. 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.
3.16.2 Networking Configuration Submenu (OnCue® Password) The networking Configuration menu includes settings used for communication with the Kohler® OnCue® Generator Management System. See Figure 3-23. 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 3-24). This includes the following optional modules: Programmable Interface Module (PIM) Figure 3-24 Networking----> Information Networking----> Status Networking----> Configuration RBUS ----> Information Modules Connected: <---- Return Remote ----> Devices 3 RD See Figure 3-25.
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 ----> 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 3-26. 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 Figure 3-27. 3.18.1 Procedure to View Event History 1.
Notes 44 Section 3 VSC Controller Operation TP-6843 1/13
Section 4 Scheduled Maintenance ! WARNING ! WARNING Accidental starting. Can cause severe injury or death. Hot engine and exhaust system. 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. Do not work on the generator set until it cools. Disabling the generator set.
4.1.1 Service Schedule, 6VSG Models Procedure System Component or Procedure See Section Visually Inspect Check Change Clean Test Frequency Fuel Flexible lines and connections X Main tank supply level (if LPG fueled) Fuel piping Lubrication R X X Crankcase breather hose Yearly X X 8 hours or before use Yearly or 500 hours Change oil Replace filter X Yearly or 100 hours ‡ X Yearly or 200 hours 4.5 Air ducts, louvers Exhaust Line Weekly 4.
4.2 Lubrication System 4.2.3 See the service schedules in Section 4.1 for oil change and oil filter replacement intervals. See the service views in Section 1.7 for the oil drain, oil dipstick, oil fill, and oil filter locations. Use 5W-30 API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner. 4.2.1 4.2.
4.3 Spark Plugs 3. Fill with oil. a. Fill the engine to the F mark on the dipstick. The engine oil capacity is shown in Figure 4-2. See Section 4.2.3 Engine Oil Recommendation, for oil selection. 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. Figure 4-2 Generator Set Model Oil Capacity, L (qt.) 6VSG 2. Remove the spark plug and check its condition.
4.4 Air Cleaner Service Precleaner Service The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Figure 4-6. Use the following procedure to wash and oil the precleaner as indicated in the service schedule. Wash and oil the precleaner more often under extremely dusty or dirty conditions. Figure 4-6 1. Press the OFF button on the generator set controller. 1 2. Disconnect the AC power to the generator set. 3.
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 loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary. 9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover.
Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. All generator set models use a negative ground with a 12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information.
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. Follow the battery charger manufacturer’s recommendations.
Section 5 Troubleshooting 5.1 Introduction 5.3.2 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. The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load.
5.5 Troubleshooting Figure 5-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Figure 5-2 Problem Possible Cause Recommended Action Controller Backlight turns off after about 1 minute with no display backlight activity. is off. 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. See Figure 1-2.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kJ km kOhm, kΩ kPa kph kV kVA kVAR kW kWh kWm kWth L LAN LxWxH lb.
Notes TP-6843 1/13 Appendix 57
Notes 58 Appendix TP-6843 1/13
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 TP-6843 1/13a © 2012, 2013 by Kohler Co. All rights reserved. For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: Call 1-800-544-2444 or visit KOHLERPower.
