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Generator Operation Manual

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1. v Contrast 50 Y Return If the exerciser has not been set No Exercise Sch will be displayed Figure 3 8 Procedure to Set the Exerciser on the VSC Controller TP 6843 7 15 Section 3 VSC Controller Operation 29 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 Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable If a setting on the controller display is flashing edit mode has been enabled Press the OFF or AUTO button to exit the edit mode 3 8 Main Menu Press the Select button once to bring up the main menu Overview is displayed See Figure 3 9 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 3 9 The controller will exit the main menu after 5 minutes if no buttons are pressed To exit the main menu immediately press the controllers OFF or AUTO button
2. Return To change the date and time press the Select button See Figure 3 7 for instructions Figure 3 20 Date and Time Menu See Figure 3 22 See Figure 3 23 See Figure 3 24 Section 3 VSC Controller Operation 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 To enable or disable DHCP and change the IP settings go to the Networking Configuration menu See Section 3 16 2 Networking gt Information Status Networking gt OnCue Status Connected gt Y y DHCP Enabled t IP Address 123 456 789 123 Subnet Mask 123 456 789 123 Gateway 123 456 789 123 DNS 1 123 456 789 123 f 123 456 789 123 Y Ethernet Status Disconnected Y OnCue Server 123 456 789 123 DNS 2 Figure 3 22 Network Status Submenu 38 Section 3 VSC Controller Operation Return TP 6843 7 15 3 16 2 Networking Configuration Submenu OnCue Passwor
3. A a Figure 1 6VSG Generator Set TP 6843 7 15 List of Related Literature Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Literature Type Part Number Installation Manual Model 6VSG Generator Set TP 6842 TP 6844 Service Manual 6VSG Generator Set Operation Manual OnCue Software TP 6796 Operation Manual SiteTech Software TP 6701 Installation Instructions Programmable Interface Module PIM TT 1584 Parts Catalog Model 6VSG TP 6845 Figure 2 Related Literature Introduction 9 Nameplate 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 KOHLER KOHLER CO KOHLER WI USA MODEL SERIAL SPEC BUILD DATE MM YY HZ RPM FUEL VOLTAGE AMPS PHASE kw KA PF GEN MODEL BAT V INSUL NEMA CLASS _ 40 C AMB KW VARIES WITH BTU CONTENT OF FUEL GM12070 Figure3 Typical Nameplate 10 Introduction Emission Information The Kohler Model CH740 engine used on the 6VSG generator set is certified to opera
4. Figure 3 11 Engine Metering Menu Figure 3 10 Overview Menu TP 6843 7 15 Section 3 VSC Controller Operation 31 3 11 Generator Metering Menu The generator metering menu displays the generator voltage and 96 load See Figure 3 12 3 11 1 Calibration A 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 The Reset Calibration menu allows you to set the readings back to the default settings after calibration if necessary See Figure 3 12 Generator gt Volts Metering 54 0V M 73 Load Reset Calibration Reset Calib No I Return Reset Calib Yes gt Calibration Reset Figure 3 12 Generator Metering Menu 32 Section 3 VSC Controller Operation TP 6843 7 15 3 12 Generator Set Information 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 compu
5. Status Overview gt Displays 12h Press the Up and Down arrow buttons to move between menus Press OFF or AUTO to exit the menus Engine gt Metering Generator gt Metering Date gt and Time Genset gt Information Network gt Information Genset gt PIM gt Run Time Status Event Log gt po Figure 3 9 VSC Main Menu 30 Section 3 VSC Controller Operation TP 6843 7 15 3 9 Overview Menu 3 10 Engine Metering Menu 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 Overview gt Active Alert 1 2h if any wai Engine gt Eng Speed Metering 2300 R min X Oil Pressure Switch OK Oil Temperature 125F a Battery Y lt Return 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 06 Return 13 3V
6. 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 voltage Generator set overloaded Reduce the load Generator set stops suddenly Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer Auxiliary winding circuit breaker tripped Reset the circuit breaker located in controller s service access area Contact an authorized Kohler distributor dealer for service if breaker trips repeatedly Fault shutdown Check the controller display for fault messages See Section 2 6 Correct the fault condition and reset the controller Generator set in the OFF mode Press the RUN button to start the engine or press AUTO to allow remote starting Remote stop command received from a remote switch or OnCue Check the remote switch position Check OnCue Engine malfunction Figure 5 2 General Troubleshooting Chart 54 Section 5 Troubleshooting Contact an authorized Kohler distributor dealer TP 6843 7 15 Appendix A Abbreviations The following list contains abbreviations that may appe
7. No engine rotation is sensed during cranking Shuts down 3 seconds after the fault is detected Check the battery Check for loose connections Contact an authorized distributor dealer for service MainPwrOverL Shutdown Main power overload An over current fault on the controller output short circuit Contact an authorized distributor dealer for service Not in Auto The generator set is not in Automatic standby mode Remote start and stop commands from a transfer switch or remote switch will be ignored Press AUTO to place the generator set in Automatic mode when appropriate Over Crank Reserve Oil Empty Three unsuccessful starting attempts The oil makeup kit reservoir bottle is empty Optional communications kit and oil makeup kit required Check the fuel supply spark plug and battery Check for loose connections Contact an authorized distributor dealer for service Add oil to the oil makeup kit reservoir Speed Sensor Fault SD Engine speed sensing has failed or engine stalled Contact an authorized distributor dealer for service Engine cooldown runs before shutting down Figure 2 5 Controller Fault Messages TP 6843 7 15 Section 2 Generator Set Operation 21 Notes 22 Section 2 Generator Set Operation TP 6843 7 15 Section 3 VSC Controller Operation 3 1 VSC Generator Set Controller All 6VSG generator sets are equipped with the
8. 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 If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area 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 particularl
9. connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire Ch 9 Risk of fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 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 Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator
10. 4 8 2 Fuel System uua n a eee 51 4 8 3 Cylinder Lubrication 0000 c eee 51 4 8 4 Exterior Preparation 0 c eee ee 51 4 8 5 Battely acoso d ex ete ED Md are e Hue XQ 52 Section 5 Troubleshooting 0 00 cece eee eee eee 53 Bl Introduction zoe e Saar AA 53 5 2 Fault Messages o n anena ni a te eee 53 5 3 Circuit Protection 0 0 0 uaaa aaaea 53 5 3 4 Controller Internal Circuit Protecti0N o 53 5 3 2 Line Circuit Breaker 0 000 cc eee eee 53 5 4 Controller Service Access 0 000 llli 53 5 Troubleshooting 0 cece eee 54 Appendix A Abbreviations ooooooooornr RR I II mh 55 4 Table of Contents TP 6843 7 15 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 This manual has several types of safety precautions and instructions Danger Warning Caution and Notice 4h DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warming indicates the presence of a
11. brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour cubic feet per minute center of gravity 7 15 CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL Cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package do
12. fault short circuit on the accessory controller power output Feeds RBUS devices PIM distributor dealer for service Aux Input Auxiliary input An optional customer connected input is closed Digital input from optional PIM Check customer supplied equipment Batt Chg Flt Battery charger fault Input to PIM from an external battery charger not the built in battery charger Check external battery charger Battery Voltage CrLow Engine starting battery voltage is critically low less than 10 5 VDC Check the battery rating and condition Check the battery charger operation Charge or replace the battery Battery Voltage Engine starting battery voltage rises above High 16 VDC for more than 10 seconds Inhibited during the engine crank cycle Check the battery rating and condition Check the battery charger operation Clears when the battery voltage returns to an acceptable level Battery Voltage Engine starting battery voltage falls below Low 12 5 VDC for more than 90 seconds when the engine is not running Check the battery rating and condition Check the battery charger operation Not operative during the engine crank cycle Charge or replace the battery Clears when the battery voltage returns to an acceptable level 20 Section 2 Generator Set Operation TP 6843 7 15 Fault Message Enclosure Intrusion Alarm Warning W or Shutdown SD Condition The encl
13. 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 Press Select to enter the main menu 2 Press the down arrow to step down to the event log 3 Press Select to display the most recent event 4 Press the down arrow to step to the next event 5 Use the up and down arrow buttons to view events 6 Press the Select button to exit the event log To stop viewing the event history before the last event press the select button to return to the main menu Date MO DA YEAR Event Log gt time HR MN event number W S l engine hours event name Press UP and Down arrow buttons to scroll through events N Date MO DA YEAR time HR MN event number W S l engine hours event name Press Select button at any time to return to the main menu Figure 3 27 Event Log TP 6843 7 15 Section 3 VSC Controller Operation 43 Notes 44 Section 3 VSC Controller Operation TP 6843 7 15 Section 4 Scheduled Maintenance A WARNING FA 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 Acciden
14. overcrank fault See Section 2 6 Cranking 1 2 and 3 are displayed during the crank cycle Pressing the OFF button during the crank cycle stops the cranking No other buttons are acknowledged during the crank cycle 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 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 2 3 e f the storage battery voltage falls below the minimum voltage for more than 3 minutes or if a remote start command is received the generator set starts A remote start command can be activated by closing the remote start contacts across 3 and 4 or by a start exercise command e When the generator set load falls below the minimum load for more than 3 minutes or a remote stop command is received the generator set stops A remote stop command can be caused by opening the remote start contacts across 3 and 4 or by the exercise time ending The minimum voltage minimum load and time delays are adjustable using a personal computer and Kohler SiteTech so
15. 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 52 Section 4 Scheduled Maintenance TP 6843 7 15 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 Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to equipment 5 2 Fault Messages The VSC controller displays fault messages to aid in troubleshooting Selected fault messages and recommended checks are listed in Figure 2 5 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 6 3 5 3 Circuit Protection If the generator set circuit breaker trips repeatedly contact an authorized Kohler distributor dealer for service 5 3 1 Controller Int
16. Exercise 1 00PM 02 12 1011 e Exercise Mode Loaded Ful Sp Exercise Freq Weekly Language English zl Contrast 50 Return If the exerciser has not been set No Exercise Sch will be displayed Figure 3 19 Genset System Menu TP 6843 7 15 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 3 20 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 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 3 21 Networking Networking gt Information Status A Y Networking gt Configuration RBUS gt Information Return Figure 3 21 Networking Information Menu TP 6843 7 5 Date and Time Date A 02Dec2011 WY Time 12 34pm Time Format 12hr
17. Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 3 Exercising the Generator Set Operate the generator set without load once each week or every 2 weeks for 20 minutes See Section 2 5 Exercise For instructions to set the exerciser see Section 3 6 2 4 Generator Set Operation 2 4 1 Start Press the RUN button to immediately start the generator set Local Starting and Stopping Stop Press the OFF button The engine stops Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown 2 4 2 Remote Starting and Stopping The generator set must be in automatic mode for remote operation Press the AUTO button on the VSC controller A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set Close the switch to start and run the generator set Open the switch to stop the generator set Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown 18 Section 2 Generator Set Operation 2 4 8 Engine Start Crank Cycle The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an
18. 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 GM89864 VSC revised GM77569 VSC original Figure 1 1 VSC Controller 1 5 1 e Six button keypad o OFF AUTO and RUN pushbuttons o Select and arrow buttons for access to system configuration and adjustment menus e LED indicators for OFF AUTO and RUN modes VSC Controller Features LED indicators for percentage of load being output LCD display o Two lines x 16 characters per line o Backlit display with adjustable contrast for excellent visibility in all lighting conditions Scrolling system status display o Generator set status Section 1 Descriptions and Service Views 13 Voltage and percent load o Engine temperature o Oil pressure o Battery voltage Engine runtime hours e Date and time displays e Smart engine cooldown senses engine temperature e Digital voltage regulation 21 096 RMS no load to full load Automatic start with programmed cranking cycle Programmable exerciser can be set to start automatically on any future day and time and run every week or every two weeks e Three exercise modes Front access mini US
19. for more information TP 6843 7 5 2 DC LI ac 1 LL IDC The VSC measures the average DC voltage on the output and lists this on the auto scrolling display in the Overview menu and in the Generator metering menu 36V 48V 6VSG Current Metering Metering KPS 105 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 Consult the battery manufacturers instructions regarding battery care and maintenance Enclosure Check that all enclosure panels and internal baffling are in place Section 2 Generator Set Operation 17 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 e 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
20. interconnection of standby and normal sources of supply Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions 7 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 battery charging alternator connections 5 Attach the weld ground connection close to the weld location Connecting the battery and the battery charger Hazardous voltage can cause severe
21. 3 18 Refer to the battery manufacturer s recommended maximum charge rate and contact an authorized Kohler distributor or dealer if the setting needs to be changed Recommended charging voltage VDC x Maximum charging current amps x 100 Load Limit 6000 watts Nominal Voltage 24V 36V 48V System Voltage VDC 27 40 5 54 Maximum Current at 100 Load Limit Amps 222 148 111 Figure 3 18 Maximum Charge Current at Default Load Limit Setting of 100 TP 6843 7 15 Section 3 VSC Controller Operation 35 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 3 14 3 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 36 Section 3 VSC Controller Operation Genset System gt A System Voltage 54 0V Y Auto Start Volt 50V Auto Stop Load 40 Load Limit 100 Iu Fuel Type Natural Gas Next
22. 3 VSC Controller Operation 10 Repeat steps 5 through 9 to change the next item on the line until the desired settings are displayed 11 Press Select to save after all settings have been selected Settings will stop flashing 12 Set the exercise frequency weekly or every two weeks Weekly exercises are recommended 13 Press the down arrow button to step to the Return menu Press the Select button to return to the main menu After a scheduled exercise run the next exercise time and date will be updated automatically based on the Exercise Frequency setting Exerciser Reset To reset the exerciser to run at a different day and or time or to change the exercise mode follow the procedure in Section 3 6 2 to change the exerciser settings TP 6843 7 15 Genset System gt A System Voltage 54 0V VY Auto Start Volt V Y Auto Stop Load S Load Limit Fuel Type Natual Gas Y Next Exercise HR MN PM MM DD YY Next Exercise HR MN PM MM DD YY O Ev d Exercise Mode Loaded Exercise Mode Loaded Full Sp Unloaded Cycle Loaded Full Sp Exercise Freq Weekly VY Exercise Freq Weekly Bi Weekly N Language English
23. 4 3 Adjusting the Display Contrast lille 36 3 15 Date and Time Menu 00 cee ee 37 3 16 Networking Information Menus l l 37 3 16 1 Networking Status Submenu 0000 eee eee 38 3 16 2 Networking Configuration Submenu OnCue Password 39 3 16 3 RBUS Information 0 0 0000 cee ee 40 3 16 4 Remote Devices Submenu 00200 eee eee 41 3 17 Programmable Interface Module PIM Status Menu 42 3318 Event LOG jc oreet A Cm MN e A ER eat 43 3 18 1 Procedure to View Event History o o oooooooo 43 Section 4 Scheduled Maintenance o ooococcnccn eee 45 4 1 Scheduled Maintenance 0 000 c eee 45 4 1 1 Service Schedule 6VSG Models o eee 46 4 2 Lubrication System 0 0000 cae 47 4 2 1 Low Oil Pressure Shutdown 0000 cee eee 47 422 Oi Check be dee when Saas Sale Pao dar ES 47 4 2 3 Engine Oil Recommendation 000e eae 47 4 2 4 Oil Change Procedure 00 cece eee ee 47 4 2 5 Resetting the Maintenance Timer 2000005 48 43 Spark Pl gsszzzi eurem DER Ries ri adria 48 44 Air Cleaner Service 0 00 cece 49 4 5 Cooling System s a ienaa wb ade hon vada tind eae EP MENDES EEG 50 4 6 Exhaust Syste bailan 50 4 7 Engine Starting Battery oooococoococccocr 50 48 Storage Procedure oooooccoccoc a e 51 4 8 1 Lubricating System 00 000 cee 51
24. 4 Air Cleaner Service The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 4 6 Cover knob Air cleaner cover Element cover nut Element cover Foam precleaner Air cleaner element Air cleaner base Figure 4 6 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 Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure TP 6843 7 5 Precleaner Service 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 1 Press the OFF button on the generator set controller 2 Disconnect the AC power to the generator set 3 Disconnect the engine starting battery negative lead first 4 Loosen the cover knob and remove the air cleaner cover Remove the precleaner from the paper element Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 5 Saturate the precleaner with new engine oil Squeeze out all of the excess oil 6 Reinsta
25. B connector for SiteTech connection Integral Ethernet connector for Kohler OnCue Built in 2 5 amp battery charger Remote two wire start stop capability Diagnostic messages o Displays diagnostic messages for the engine generator and programmable interface module PIM o Over 70 diagnostic messages can be displayed Maintenance reminders System settings o System voltage and percent load o Voltage adjustment Measurement system English or metric PIM status Programmable Interface Module displays o nput status active inactive o Output status active inactive 14 Section 1 Descriptions and Service Views 1 6 Accessories The following optional accessories are offered for the 6VSG generator sets 1 6 1 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 Carburetor Heater See the generator set Installation manual for more information 1 6 2 OnCue Generator Management System The Kohler OnCue Generator Management System allows monitoring and control of your 6VSG generator set from a personal computer located in your home or at other remote locations OnCue can also be configured to send email or text message notifications in the event of a generator set fault Note Be su
26. 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 From Figure 3 24 Remote gt Devices O S N XXXXXXXXX S N XXXXXXXXX Return 1 1 lt lt DeviceType gt gt lt lt DeviceType gt gt A A VI E Module Status Connected 1 Comm Errors 12345 Comm Timeouts 12345 Module ID 12 1 Firmware Ver 122 1 Dis Connected e lia Pes i date and time that the MM DD YY 12 12 PM Suite was connected Disconnected Displays the last date and time of 1 successful communication Return Figure 3 25 Remote Devices Submenu TP 6843 7 15 Section 3 VSC Controller Operation 41 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 Inp
27. Operation DC Generator Sets Models 6VSG 24VDC 36VDC 48VDC Controller VSC 7 2901 mmt POVER SYSTEMS KOHLER o Power Systems TP 6843 7 15b California Proposition 65 A 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 Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information ooooooooonnoan IIR 2 Safety Precautions and InStructiONS oo oocooooccrnrnn nnn 5 Introduction e BN ee ee eee 9 Service Assistance te a
28. VSC generator set controller The VSC controls generator set and the optional Programmable Interface Module PIM or Communications Kit The VSC controller features include e Two line x 16 character backlit digital display with adjustable contrast e OFF AUTO and RUN generator set master control buttons e Generator set status indicating LEDs OFF AUTO RUN e Up Down and Select buttons for navigation through menus and adjustments Power system indicator LEDs to show power output of the generator TP 6843 7 5 3 2 Control and Indicators Figure 3 1 illustrates the VSC controller See Figure 3 2 for details of the controller s user interface GM77569 GM89864 1 User interface see Figure 3 2 2 Service access see Section 5 4 3 USB connection Figure 3 1 VSC Controls and Indicators B at J Y ca 515 y N OFF AUTO RUI Jono ad coofjooo KPS_050 GM81498 2 line LCD display Up button Select button Down button RUN button and LED 100 load LED 7596 load LED 50 load LED 2596 load LED OFF button and LED AUTO button and LED Figure 3 2 VSC User Interface Section 3 VSC Controller Operation 23 3 2 1 Controller Keypad 3 2 2 LED Indicators The RUN OFF and AUTO buttons control the LEDs above the RUN OFF and AUTO buttons generator set as described in Figure 3 3 indicate the mo
29. VSC Controller Operation 33 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 Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable 3 14 1 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 System Voltage Auto Start Voltage Auto Stop Load Load Limit Note Changing these settings can damage your generator set and batteries Always refer to the information provided by the battery bank manufacturer for the correct voltage and charge current limits for your batteries Contact an authorized Kohler distributor or dealer for assistance if the default settings are not appropriate for the battery bank 34 Section 3 VSC Controller Operation System Voltage T
30. aan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6843 7 15 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Service Assistance 11 Notes 12 Service Assistance TP 6843 7 15 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 2 Engine The generator set has a four cycle twin cylinder air cooled Kohler engine The engi
31. ar 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 cfh cfm CG TP 6843 ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center
32. ar or damage Air cleaner and precleaner service T Weekly Yearly or 100 hours Spark plugs Replace stepper motor coupling and bushing Yearly or 300 hours 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly Brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 years General Condition of Equipment Evidence of vibration leakage excessive noise temperature or deterioration X Weekly Interior of sound enclosure X Quarterly Not necessary for maintenance free batteries T Service more frequently under extremely dusty dirty conditions t Yearly or 250 hours if equipped with optional Oil Makeup Kit Megger is a registered trademark of Biddle Instruments 46 Section 4 Scheduled Maintenance X Action D Authorized distributor dealer only R Replace as necessary TP 6843 7 15 4 2 Lubrication System 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 4 2 1 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
33. ble Note Run the generator set monthly whenever possible 4 8 1 1 Operate the generator set until it reaches operating temperature or about 15 minutes Lubricating System 2 Stop the generator set 3 While the engine is still warm drain the engine lubrication oil from the engine crankcase 4 Refill engine crankcase with oil See Section 4 2 3 for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set 4 8 2 Fuel System 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Press the OFF button on the generator set controller 4 8 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs 3 Crank the engine two or three revolutions to lubricate the cylinders 4 8 4 Exterior Preparation 1 Clean the exterior surface of the generator set 2 Seal all openings in the nonabsorbent adhesive tape engine with 3 Mask all areas to be used for electrical contact 4 Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion Section 4 Scheduled Maintenance 51 4 8 5 Battery Perform battery storage last 1 Press the OFF button on the generator set controller 2
34. cal reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 5 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 Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive
35. d The networking Configuration menu includes settings used for communication with the Kohler OnCue Generator Management System See Figure 3 24 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 For applications that require static IP addresses press and hold the select button to enable editing disable DHCP and then step to the next parameters and enter the information Networking gt Networking gt Information Status a If an error occurs while setting a parameter an error message is displayed and then the controller exits the edit mode Previous settings are preserved Password For the initial OnCue setup you will be required to reset the OnCue password on the VSC controller and then enter it into the OnCue software To reset the password follow the instructions in Figure 3 22 Note The password is displayed for only 10 seconds Be sure to write down the password and serial number A new password is generated each time the reset password procedure is performed If the password is reset after the OnCue system has been set up the connection will be lost Enter the new password in OnCue to reconnect Networking Configura
36. d Press the Select button to exit the menu Press the AUTO or OFF button to exit the main menu Note If no buttons are pushed the controller exits the menus and returns to the generator set status display after 5 minutes TP 6843 7 15 Changing Date Time 1 Press the Select button to enter the main menu O Overview gt Display 12h 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 gt Display and Time DA 3 Press the Select button to enter the Date and Time menu Date Press 05Dec2011 O Display 4 To change the date and time settings press the Select button again The year will flash O Date Display ind 05Dec2011 5 Press the up or down arrow buttons to change the year ZN Date Display Eoy 05Dec2012 6 When the correct year is shown press the Select button The year is saved and the next setting month flashes 9 Date Display Ad 05Dec2012 7 Repeat steps 5 and 6 using the arrow and select buttons to set the month and the date Figure 3 7 Changing Settings TP 6843 7 15 8 When the correct date is shown press the Select button The saved date is shown Press Display 9 Press the down arrow button to
37. d 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 See Figure 4 7 for typical battery connections 2 E e KPS_030 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 4 7 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 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 To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease TP 6843 7 15 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 availa
38. de of operation as shown in Figure 3 4 Use the Select Up arrow and Down arrow buttons to Load indication LEDs indicate the load on the navigate through the menus and change settings if generator set A steadily lighted LED indicates that necessary See Section 2 4 for operation instructions 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 increases Button Button Function Starts the generator set The engine start time delay is ignored Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press OFF to clear faults and reset the controller AUTO Places the generator set in Automatic standby mode Down arrow Use to navigate through menus and change settings This manual contains instructions Select to navigate the controller menus and adjust settings on the VSC controller Up arrow Figure 3 3 VSC Controller Pushbutton Operation LED Operation Lights when the generator set has been started locally by pressing the RUN button Remote start and stop commands are ignored Lights for 2 seconds then flashes every 2 seconds when the generator set and controller are off Remote start stop commands have no effect The exercise cycle will not run In Auto mode OFF LED flashes quickly to indicate a fault shutdown Attention required I
39. dentify and correct the fault condition before resetting the controller Lights when the generator is in automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands or an ATS Time delays operate as described in Section 2 4 25 load LED flashes and stays on longer as load increases from 1 to 25 50 load LED flashes and stays on longer as load increases from 26 to 50 75 load LED flashes and stays on longer as load increases from 51 to 75 100 load LED flashes and stays on longer as load increases from 76 to 100 Figure 3 4 VSC Controller LED Operation 24 Section 3 VSC Controller Operation TP 6843 7 15 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 When a fault or warning condition exists the controller will show the corresponding message See Section 2 6 for more information about faults Controller menus display power system information including status information for the engine generator and optional RBUS acces
40. ed to 5 for 6 minutes to allow the generator to cool down before stopping 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 Selected fault messages are shown in Figure 2 5 2 6 1 The controller displays a fault message but the generator set does not shut down on a warning The controller resets automatically after a warning condition is corrected 2 6 2 Shutdowns Under a fault shutdown condition the generator set shuts down automatically and the controller displays a fault message The OFF LED flashes In some cases the engine cooldown cycle runs before the engine shuts down See Figure 2 5 Warnings Shutdown switches such as the low oil pressure switch or high engine temperature switch on the generator set will automatically reset when the problem is corrected However the fault condition at the controller does not clear until the controller is reset The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 3 for instructions to reset the controller after a fault shutdown Section 2 Generator Set Operation 19 2 6 3 Resetting the Contro
41. ernal 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 for service TP 6843 7 5 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 If the circuit breaker trips reduce the load and switch the breaker back to the ON position 5 4 Controller Service Access A USB port is located in the service access area original controller or on the front panel revised controller See Figure 5 1 Some controller settings can be adjusted using a laptop computer with Kohler SiteTech software Use a USB cable with a mini B connector to connect the controller to your PC See TP 6701 SiteTech Software Operation Manual for more information KPS 031A GM77569 Revised 1 USB port mini B 2 Not used Figure 5 1 Controller Service Access cover removed Section 5 Troubleshooting 53 5 5 Troubleshooting Figure 5 2 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Problem Controller display backlight is off Possible Cause Backlight turns off after about 1 minute with no activity Recom
42. ftware Contact your Kohler distributor TP 6843 7 15 E _ SES KPS_043B 1 Positive 2 Negative Figure 2 3 Output Block 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 and time and then to set the exerciser See Section 3 1 VSC Generator Set Controller for more information An exercise can be started at any time using Kohler OnCue or can start automatically according to the exercise schedule programmed on the VSC controller Three exercise modes are available During some exercise modes the engine speed increases and decreases This is normal 1 Unloaded Full Speed Exercise The generator regulates the output load below 5 of capacity The generator will stop after 20 minutes 2 Unloaded Cycle Exercise The generator set engine speed varies during the 20 minute exercise according to the following cycle a The generator set regulates the output load below 5 of capacity for 11 minutes to warm up b The output regulation is moved to the Genset Maximum Percent Capacity for 3 minutes to test ability to output power TP 6843 7 15 c The load limit is return
43. gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers mproved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz Appendix 55 kJ kOhm kQ kPa kph kV kVA kVAR kWh kWm kWth LAN LxWxH Ibm ft3 m3 m3 hr m3 min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height
44. hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6843 7 15 Accidental Starting A WARNING Das Ye 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 Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set OFF RESET button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generat
45. he system voltage is the output voltage of the generator set Default values are shown in Figure 3 15 The system voltage is set to the required output voltage to properly support the load and charge the battery Do not confuse this value with the voltage designation of the battery stack For example four 12V batteries in series results in a 48V battery stack but the output voltage needed to charge the battery stack is 54V 24V 36V 48V 27 40 5 54 Nominal Voltage Default System Voltage VDC Figure 3 15 System Voltage Default Settings Refer to the battery manufacturer s documentation for the recommended charging voltage If the system voltage needs to be changed contact an authorized Kohler distributor or dealer Note 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 3 15 will have an output of 6 kW If the system voltage is set to a higher value the output current decreases The available power output also decreases below 6 kW due to the limits on the engine speed The graphs in Figure 3 17 illustrate the effect of changing the system voltage 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 3 16 Nominal Voltage Default Auto Start Voltage VDC F
46. i psig pt PTC PTO PVC qt qty R rad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs RTU RTV RW SAE scfm SCR S Sec SI SI EO sil SMTP SN SNMP SPDT National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board ofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory RS 485 proprietary communications relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors remote terminal unit room
47. igure 3 16 Auto Start Voltage Note The 3 minute 180 second time delay can be changed using a personal computer laptop and Kohler SiteTech software Contact a Kohler authorized distributor or dealer to adjust the delay setting if necessary TP 6843 7 15 Model 6VSG 24V Model 6VSG 36V Available Available Current Current 3 t Operation tem e pr volinge gray oltages gray oltages 222 iss VDC 148 37 VDC 40 5 VDC i Typical Area Typical Area of Operation of Operation dark gray dark gray 125 113 45 78 0 j j Engine Speed 0 7 j Engine Speed 2300 2900 RPM 2300 2900 RPM Typical performance Model 6VSG 54V Allowable Area of Operation bein gray oltages 111 51VDC savypc 79 50 0 2300 2900 ErgineSpeed RPM 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 Load Limit This setting limits the current output to the maximum charge rate specified by the battery manufacturer or load in the application The default setting is 100 which gives the maximum current values shown in Figure
48. ii E TP EN TEMP 19 262 SRULIOWNAS is irt Aces RR RD e a RU DRE Et I 19 2 6 38 Resetting the Controller After a Fault Shutdown 20 Section 3 VSC Controller Operation 00 00 nnn 23 3 1 VSC Generator Set Controller liliis 23 3 2 Control and Indicators iles eese 23 3 2 1 Controller Keypad 0000 cece essere 24 3 2 2 JEED ndiCatorS tenor ia a o dicte cac age 24 3 23 LCDDisplay sseeeesee ns 25 3 8 Controller Power 0 0 0 0c eens 26 3 4 Battery ChargidQ 0oococccoccocnanr 26 3 5 ChangingSettings llis 26 3 5 14 Procedure to Change SettingS 0oooooooomomo 26 3 6 Setting the Exerciser liliis 28 3 6 1 Setting the Exerciser at Controller Power up 28 3 6 0 Changing the Exercise SettingS o ooooooooo 28 3 7 VSC Controller Menus elei eh 30 3 8 Main Med oococccccc eee 30 3 9 Overview Menue eiaeaen ea aa ern 31 3 10 Engine Metering Menu 0 cee II 31 3 11 Generator Metering Menu 02 00 32 3 11 1 Calibration n aea a eens 32 3 12 Generator Set Information Menu 0 000 cee ee 33 3 13 Genset Run Time Menu 0 000 c eee eae 33 3 14 Genset System Menu o ooocccccoc ae 34 TP 6843 7 15 Table of Contents 3 Table of Contents 3 14 1 System Parameters for Battery Bank Charging 34 3 14 2 Setting the Exerciser 0 0 00 illie 36 3 1
49. injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Heavy Equipment 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 8 Safety Precautions and Instructions Hot Parts 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 The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts TP 6843 7 15 In
50. ll the paper element precleaner element cover element cover nut and the air cleaner cover Secure the cover with the cover knob 10 Reconnect the AC power to the generator set 11 Reconnect the generator set engine starting battery negative lead last 4 5 Cooling System The engine fan draws cooling air through the openings in the sides The alternator fan draws cooling air through an opening on the side wall of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See the service view in Section 1 7 for air intake and exhaust locations To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above them Overheating and severe generator damage may occur 4 6 Exhaust System Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components for cracks leaks and corrosion Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is clear 50 Section 4 Scheduled Maintenance 4 7 Engine Starting Battery A WARNING
51. ll the precleaner over the paper element 7 Reinstall the air cleaner cover Secure the cover with the cover knob 8 Reconnect the power to the battery charger 9 Reconnect the generator set engine starting battery negative lead last Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule Replace the paper 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 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element 7 Replace the element if it is dirty bent or damaged Section 4 Scheduled Maintenance 49 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 Reinsta
52. ller 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 While the fault message is displayed press the Select button to go to the Overview menu 9 Fault Message Overview gt 12h 2 Press Select again The active fault message is displayed NO is 3 Press Select Confirm Clear Fault displayed 4 Press the UP arrow button Confirm Clear Fault YES is displayed 5 Press the Select button to enter YES and clear the fault 6 Press the Select button to return to the overview menu The controller changes to OFF mode 7 Press AUTO to put the generator set into automatic mode po Confirm Clear 8 Fault NO Fault Message Press UP arrow button IN 2 Confirm Clear Fault YES Figure 2 4 Clearing a Fault on the VSC Controller Warning W or Fault Message Shutdown SD Condition tp6809 Contact an authorized Accy PwrOver Warning Accessory Power Overload Too many devices on the accessory power port or an over current
53. ly by an authorized Kohler distributor dealer or authorized representative The following procedure explains how to change settings See Figure 3 7 for an example using the Date and Time settings Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable 26 Section 3 VSC Controller Operation 3 5 1 1 2 11 Procedure to Change Settings Press the Select button to enter the main menu Press the down arrow button until the desired menu is displayed Press the Select button to enter the genset system displays See Figure 3 10 Press the down arrow button to step through the generator set system settings To change any of the genset system settings press the Select button The selected setting flashes Press the up or down arrow buttons to increase or decrease the setting When the desired setting is shown press Select The value stops flashing If there are additional adjustable settings on the screen the next setting flashes For example in the date menu the day month and year can be adjusted The settings are saved on completion of step 7 Repeat steps 6 and 7 for each setting on the screen Press the down arrow to step to the next screen To exit press the down arrow button until Return is displaye
54. mended Action 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 The generator set does not crank Battery weak or dead Recharge or replace the battery Battery connections reversed or poor Check the connections Fault shutdown Check the controller display for fault messages See Section 2 6 Correct the fault condition and reset the controller Generator set in the OFF mode Press the RUN button to start the engine or press AUTO to allow remote starting The generator set cranks but does not start starts hard lacks power or operates erratically Air cleaner clogged Clean and or replace the air cleaner Battery weak or dead Battery connection poor Recharge or replace the battery Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Fuel pressure insufficient Engine malfunction Check the fuel supply and valves Contact an authorized Kohler distributor dealer No DC output Line circuit breaker in the OFF position Line circuit breaker tripping because of overload Place the circuit breaker in the ON position Reduce the load on the generator set
55. ne operates on cleanburning natural gas or LPG fuel Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions Dependable maintenance free electronic ignition Precision formulated cast iron construction of parts subjected to the most wear and tear Field convertible multi fuel systems that allow fuel changeover from natural gas to LPG and vice versa while maintaining CARB emission certification The variable speed engine runs at 2300 rpm at no load and 2900 rpm when supplying full load 1 3 Generator Set Enclosure The generator set is housed in a steel enclosure with Power Armor powder coat paint The enclosure has a hinged locking door that allows easy access to the generator set controller when required but locks securely to prevent unauthorized access To open the door insert the tool provided with the enclosure and turn counterclockwise 1 2 turn Be sure to close and lock the enclosure and keep the tool in a secure location TP 6843 7 5 1 4 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 1 5 Controller The Model 6VSG generator set comes equipped with the VSC controller See Figure 1 1 The controller provides integrated
56. o EMI 11 Section 1 Descriptions and Service Views 000 eee eee eens 13 TA JIntrod ction ue km rg HR E dr se oe ee ees 13 12 Engine dE Re tm Pe a pmo e Ri ee emet 13 1 3 Generator Set Enclosure 0 aaea eee 13 14 Alternators oso fad eee Pe ee MES Rea EPA e 13 15 2Gonttoller o ee Pease a A Res Gk Ghee acne 13 1 5 1 VSC Controller Features 0 00002 eee eee 13 1 6 ACCESSOTIES fos see Ae EEG e can S nee o rd 14 1 6 1 Carburetor Heater 0 0000 eee 14 1 6 2 OnCue Generator Management SysteM 14 1 6 3 Programmable Interface Module PIM 14 1 6 4 Communications Kit 0 0 14 1 7 Service VIeWS cech ee ete US a Ba gd EA 15 Section 2 Generator Set Operation 00 0 cece eee 17 2 1 Theory of Operation ipe iaee pit a a r E ee 17 2 2 Prestart Checklist rice iare ranen de Cheeta he tine yd NDERES 17 2 3 Exercising the Generator Set 0000 iliis 18 2 4 Generator Set Operation liliis iles 18 2 4 4 Local Starting and Stopping 0 000 less 18 2 4 2 Remote Starting and Stopping liiis sess 18 2 43 Engine Start Crank Cycle 0 0000 esee 18 2 44 Engine Cooldown lees ees 18 2 4 55 Automatic Operation eese 18 2 5 Exercises du osa bb Soe hele eo e tw VE ERE eie Ro alas 19 2 6 FaullS set euo di ta NUR NERIS E E aM dE EN 19 2 631 Waring ssec vate aes Ob ghee
57. or set wait 1 minute and then recheck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fixleaks and recheck the oil level c Reinstall the roof panel and close service door 5 Reset the maintenance timer on the controller 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 48 Section 4 Scheduled Maintenance 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 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable 3 Check the spark plug gap using a wire feeler gauge See Figure 4 3 for the recommended spark plug gap Adjust the gap by carefully bending the ground electrode See Figure 4 4 and Figure 4 5 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29 8 Nm 18 22 ft Ib Generator Set Model Spark Plug Gap 6VSG 0 76 mm 0 030 in Figure 4 3 Spark Plug Gap KPS_027 KPS_028 Figure 4 5 Adjusting the Spark Plug Gap TP 6843 7 15 4
58. or set by the remote start stop switch Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin 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 Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemi
59. osure door is open Optional communications kit required Check for evidence of unauthorized access to the generator set Close and lock the enclosure door Engine Oil Pressure Low 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 Fuel Pressure Low The fuel pressure switch measures low fuel pressure below 4 5 inches water column Optional communications kit required Check fuel supply and fuel lines Engine Speed High Engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service Exer Not Sch Exercise not scheduled No exercise is scheduled on the controller See Section 3 6 for instructions to set the exerciser Generator VoltageL1 L2 High Generator voltage high Output voltage exceeds 12096 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Lo Crank VIt Low cranking voltage Battery voltage falls below 8 VDC for more than 6 seconds while the starter is engaged Charge or replace the battery Locked Rotor
60. other malfunction Low Oil Pressure Shutdown Note The LOP shutdown feature does not protect against damage caused by operating when the oil level is low it is not a low oil level shutdown Check the oil level regularly and add oil as needed 4 2 2 Oil Check The generator set is shipped with oil Before operating the generator set check the engine oil in the crankcase See Figure 4 1 Maintain the oil level at or near not over the full mark on the dipstick Add 5W 30 synthetic oil when the oil level is low Check the oil level before each use For extended operation check the oil level every 8 hours Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil Figure 4 1 Oil Check typical TP 6843 7 15 4 2 3 Engine Oil Recommendation 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 4 Oil Change Procedure Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Drain the oil while it is still warm 1 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 hou
61. pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQ milliohm MOhm MQ megohm MOV MPa mpg mph MS ms m sec nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight 56 Appendix NPSC NPT NPTF NR ns OC OD OEM OF opt OSHA OV Oz P PP PC PCB pF pic PF ph Y PHC PHH PHM PLC PMG pot ppm PROM ps
62. re to obtain the correct version of the OnCue kit for the VSC controller OnCue version 3 1 or higher is required for 6VSG generator sets 1 6 3 Programmable Interface Module PIM The optional Programmable Interface Module PIM provides two programmable inputs and six programmable dry contact outputs for connection to customer supplied equipment The outputs are controlled by the VSC controller and can also be controlled remotely using the OnCue program The PIM is mounted in a NEMA 3R aluminum enclosure which can be mounted indoors or outdoors See the installation instructions provided with the PIM 1 6 4 Communications Kit The optional communications kit includes the following factory installed items Interface board with factory set inputs and outputs and customer connection terminal blocks Fuel pressure switch e Enclosure intrusion alarm switch TP 6843 7 15 1 7 Service Views kps 002 eps ADV 8060 Exhaust air outlet Lifting hole Air cleaner Controller Oil fill Engine certification label Oil drain Load circuit breaker Oil drain valve Oil dipstick Oil filter Exhaust outlet Muffler Fuel inlet Alternator air inlet Electrical inlet Customer connection blocks located behind panel Battery cables included Electrical inlet access panel Nameplate Engine starting batte
63. ry 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 Repeat until all settings are saved and the controller returns to the main menu See Section 3 5 for more detailed instructions to change settings on the VSC See Section 3 6 for more detailed instructions to set the exerciser or change the exercise settings 3 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The VSC controller monitors the battery voltage and provides a constant 13 8 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz power on a breaker protected circuit for the built in battery charger 3 5 Changing Settings Some settings can be changed from the controller keypad The controller settings and generator set output 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 Have controller setup and adjustment performed on
64. ry location battery not included ZOovoouoosrom k Figure 1 2 Service View see Figure 1 3 for optional communications kit components TP 6843 7 15 Section 1 Descriptions and Service Views 15 ComKitB GM85956C 1 Interface board factory wired to terminal blocks 2 Intrusion alarm switch 3 Interface board input and output connection terminal blocks 4 Fuel pressure switch Figure 1 3 Optional Communications Kit Components 16 Section 1 Descriptions and Service Views TP 6843 7 15 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 24V 6VSG Current Metering Current Metering KPS 106 Figure 2 2 Output Waveform with Rectified Signal The voltage is regulated to maintain a constant output voltage which is equal to the System Voltage setting When the load on 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 The output current and power increase with the engine speed The engine speed is limited to a maximum of 3300 rpm See Section 3 14 1
65. set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of any building adjacent to the generator set Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following Light headedness dizziness Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly bl
66. severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble TP 6843 7 15 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent
67. sing service door and remove roof panel e Clean the area around the dipstick and oil fill cap f Remove the screw in plug on drain fitting in skid rail g Open the oil drain valve on the engine Remove the dipstick and oil fill cap Allow time for the engine oil to drain completely i Close the oil drain valve Replace the cap in skid rail j Replace the dipstick 2 Replace the oil filter a Clean the area around the oil filter Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the gasket sealing surface of the oil filter adapter c Apply a light coat of clean oil to the rubber seal of the new oil filter d Install the new oil filter following the instructions provided with the filter Section 4 Scheduled Maintenance 47 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 Generator Set Model Cil Capacity L qt 6VSG 1 9 2 0 Figure 4 2 Engine Oil Capacity b Reinstall the dipstick and the oil fill cap c Reconnect the generator set engine starting battery negative lead last d Reconnect the AC power to the generator set e Press the RUN button on the generator set controller The generator set will start f Run the generator set for a minute to allow the oil pressure to reach operating range g Stop the generat
68. sories exercise settings and event history Some menus allow changes to the controller settings See Sections 3 7 through 3 18 for menu diagrams gt gt gt Active Alert a Genset Status Running Voltage 54V Load 73 mE Engine 125F Oil Pressure Okay Owo Battery 13 3V Engine Runtime 100 6 h Y Date 02DEC2011 Time HR MNpm Sample data shown Figure 3 5 Autopaging Displays Generator Running TP 6843 7 5 The display contrast is adjustable Navigate to the Genset System menu and step down to the Contrast Screen Press the Select button and then use the up and down arrow buttons to adjust the contrast See Section 3 5 Changing Settings and Section 3 14 Genset System Menu The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Active Alert Genset Status Standby Engine Runtime 100 6 h Y Date 02DEC2011 Time HR MNpm Y Next Exercise 09 00p 09Dec2011 Y Next Maintenance 150 h or Mar2012 Sample data shown Figure 3 6 Autopaging Displays Automatic Mode Section 3 VSC Controller Operation 25 3 3 Controller Power The VSC controller is powered by the generator set engine starting battery and the built in batte
69. step to the next menu Date 03Jan2012 Time Press 01 49pm Display O 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time Note To change from am to pm press the up arrow key to increase the hour until the correct hour and pm is displayed 11 In the time format menu press Select and then press the up or down arrow button to change the format 12 hr or 24 hr Press Select to save the displayed format 12 Press the down arrow button Return is displayed lt Return Press Display Nur 13 Press Select to return to the Date and Time menu Date gt Press Display O and Time 14 Press the Up or Down arrow buttons to step to a different menu 15 Press Auto to signal the controller to exit the menus and return to the generator set status display AUTO Genset State Press Standby Display Note If no buttons are pressed the controller returns to the status display after 5 minutes Section 3 VSC Controller Operation 27 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 e
70. subject to extreme weather long operating hours or dusty or dirty conditions more frequently Contact an authorized distributor dealer for parts Section 4 Scheduled Maintenance 45 4 1 1 System Component or Procedure Service Schedule 6VSG Models See Section Procedure Visually Inspect Check Change Frequency Fuel Flexible lines and connections X Quarterly Main tank supply level if LPG fueled Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil Yearly or 100 hours t Replace filter Yearly or 200 hours Cooling Air ducts louvers Exhaust Line Yearly Leakage Insulation fire hazards Obstructions or combustible materials near exhaust outlet DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect boots Yearly Battery electrolyte level and specific gravity AC Electrical System Yearly Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Wire abrasions where subject to motion Quarterly 6 months Wire cable insulation condition Engine and Mounting 3 years or 500 hours Visible we
71. tal starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set OFF RESET button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch e X Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 6843 7 15 A 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 The engine and exhaust system components become extremely hot during operation 4 1 Scheduled Maintenance Refer to the following service schedules and the runtime hours displayed on the controller display to schedule routine maintenance Intervals are shown in hours of operation and or time intervals i e weekly monthly quarterly etc Have an authorized distributor dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units
72. te using natural gas or LPG fuel The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB or EPA emission requirements Figure 4 provides the engine compliance period in hours associated with the category descriptor which may be found on the certification label Emission Compliance Period Category C Category B Category A 250 hours 500 hours 1000 hours Moderate 125 Extended 500 Intermediate hours 250 hours hours Figure 4 Emission Compliance Period Refer to the certification label for engine displacement The exhaust emission control system for the CH740 engines 6VSG is EM for U S EPA California and Europe See Figure 1 2 for engine certification label location TP 6843 7 15 For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power Systems 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 e Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristall
73. temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer simple mail transfer protocol serial number simple network management protocol single pole double throw SPST spec specs sq Sq cm sq in SMS SS std stl tach TB TCP TD TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo single pole single throw specification specification s Square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF 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
74. ter running Kohler SiteTech software is required to enter the generator set model number and serial numbers on a replacement controller Contact an authorized Kohler distributor dealer for service Genset gt Information Genset M N 6VSG 48V I M A NY DN Genset S N THHHHHHE Controller S N THHHHHHE Return Figure 3 13 Generator Set Information Menu TP 6843 7 15 3 13 Genset Run Time Menu The data shown in Figure 3 14 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 Section 4 Scheduled Maintenance for maintenance instructions After changing the oil and performing other recommended maintenance go to the Overview menu to reset the maintenance timer See Section 4 2 5 for instructions to reset the maintenance timer Eng Runtime 100 6 h X IET Eng Starts 127 Next Maintenance 150 h or Mar2012 lt Return Genset gt Run Time Figure 3 14 Generator Set Run Time Menu Section 3
75. tion Reset OnCue Password Reset OnCue Password No WY UP arrow for YES Down arrow for NO 3 Reset OnCue Password Yes Press Select to enter YES O or NO as displayed New password is displayed for DHCP Enabled approximately 10 seconds x S N 1234567 New PW 12345 v Return Nz Figure 3 23 Network Configuration Submenu TP 6843 7 15 Section 3 VSC Controller Operation 39 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 Networking gt Information Networking gt Status A xd qs Networking gt Configuration RBUS gt Information Modules Connected Return E Remote gt Devices y Net Cycle Time 123ms i Module Timeouts 1234 Module Errors 1234 Figure 3 24 VSC Information Submenu 40 Section 3 VSC Controller Operation Return See Figure 3 25 TP 6843 7 15 3 16 4 Remote
76. troduction 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 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 Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition NN EA _ _ t o SS
77. uble pole double throw double pole single throw disconnect switch digital voltage regulator EPROM EEPROM E emer ECM EDI EFR e g EGSA EIA EI EO EMI emiss eng EPA EPS ES ESD est E Stop etc exh ext electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust external Fahrenheit female FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GR gr wt HxWxD HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IBC IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor
78. urred vision Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air TP 6843 7 15 Fuel System A WARNING HE Y 4 W 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 Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Gas fuel leaks Explosive fuel vapors can cause
79. ut and output settings cannot be changed from the VSC controller s user interface PIM Status A personal computer running Kohler9 SiteTech software is required to change the input and output settings for the PIM Contact an authorized distributor or dealer for service The Kohler OnCue Management System can be used to turn the PIM outputs on and off See the OnCue Software Operation Manual for instructions The input and output settings for the communications kit interface board are factory set and locked Input 1 In Active Input 2 In Active t Output 1 In Active Y Output 2 In Active i Output 3 In Active f Output 4 In Active A Output 5 In Active v Output 6 In Active x O lt Return PIM Status displays the interface board status if the optional communications kit with factory installed interface board is installed Figure 3 26 Programmable Interface Module PIM Status Menu 42 Section 3 VSC Controller Operation TP 6843 7 15 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
80. watt withstand and closing rating with write only without weight transformer TP 6843 7 15 Notes TP 6843 7 15 Appendix 57 TP 6843 7 15b 2012 2013 2015 by Kohler Co All rights reserved KOHLER Power Systems 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 For the nearest KOHLER authorized installation service and sales dealer in the US and Canada Call 1 800 544 2444 or visit KOHLERPower com
81. xerciser 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 5 for more detailed instructions to change settings on the VSC If the battery is disconnected and reconnected during generator set maintenance or service the time date and exercise settings will need to be re entered 3 6 2 Changing the Exercise Settings This section explains how to change the exercise settings after the initial setup Follow the procedure below and see the flowchart in Figure 3 8 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 Figure 3 9 3 Press the down arrow button to step to the Genset System menu 4 Press the Select button to enter the Genset system menu See Figure 3 11 5 Use the down arrow button to step to the Next Exercise menu f the exerciser is not set No Exercise Scheduled will be displayed 6 Press and HOLD the Select button to enable editing 7 Press the Select button The setting flashes to show that it can be changed For example HR flashes to show that the hour can be changed 8 Press the Up or Down arrow buttons to change the setting 9 Press the Select button to save the setting and move to the next For example save HR setting and move to MN 28 Section
82. y 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 Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together TP 6843 7 15 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 groun

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