Kohler 48VDC manual

Operation TP-6843 1/13a DC G enera tor Set s Models: 6VSG 24VDC 36VDC 48VDC Controller: VSC[...]

Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. California Proposition 65 W ARNING ! Product Identification Information Produc t identifi cation nu mbers de termine ser vice parts. Record the p roduct iden tification n umbers i n the s paces bel ow imm[...]

TP-6843 1/13 Table of Contents 3 Figure 1-1 Table of C ontents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Safety Pr ecautions and Instructi ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . [...]

Table of Contents 4 Table of Contents TP-6843 1/13 3.14.1 System Parameters fo r Battery Bank Charging . . . . . . . . . . . . . 34 3.14.2 Setting th e Exercise r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.14.3 Adjusti ng the Displ ay Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . 36 3.15 Date and Tim e Men[...]

TP-6843 1/13 Safety Precautions and Instructions 5 Safety Precautio ns and Instruction s IMPOR T A NT SAFET Y INSTRUCTI ONS Electr o-mechan ical eq uipment, includ ing generat or sets, tran sfer swi tches, switchgea r , and acce ssories, can cause bodily harm an d pose lif e-threat ening danger when i mprop erly in stalled, operat ed, or maintained[...]

6 Safety Pre cautions and Instructions TP-6843 1/13 Battery gases . Explosion can cause s evere injury or dea th. Battery gases c an caus e an e x plos ion. Do not smoke o r permi t flame s or spa rks to occur nea r a battery at any time, p articularly w hen it is charging . Do not dispo s e of a batter y in a fire. T o pr even t bur ns an d spark [...]

TP-6843 1/13 Safety Precautions and Instructions 7 Fuel System The fuel syste m. Explosive fuel vapors can cause sever e injury or death. V aporized fuel s are hig hly explos ive. Use extreme c are whe n handlin g and storing fuels. S tore fuels in a well -ventilat ed area awa y from spa rk-produ cing equipment and out of the reach of ch ildren. Ne[...]

8 Safety Pre cautions and Instructions TP-6843 1/13 Weld ing on the generator set. Can cause s evere el ectrical equipme nt damage. Bef ore welding on the generato r set perform the followin g step s: (1) Remove the battery cables, negativ e (–) lead fi rst. (2) Discon nect all engi ne electronic con trol mo dule (ECM) conn ectors. (3) Disconn ec[...]

TP-6843 1/13 Introduction 9 Int roduc tion This man ual provide s operation and maintenanc e instructio ns for the DC (d irect curre nt) vari able speed model 6VS G generator sets equipped wi th Kohler V SC generato r set co ntrollers. This gen erator set is approve d for use in stationary applica tions in locati ons ser ved by a public utilit y , [...]

10 Introduction TP-6843 1/ 13 Nameplate The fol lowing i llustratio n shows a typical generat or set nameplate . Co py the model, ser ial, a nd spec ification numbers from the nameplate into the spaces prov ided in the pro duct infor mation s ection on th e inside front cove r of this manua l. See the s ervice vi ews in S ection 1.7 for th e namepl[...]

TP-6843 1/13 Service Assistance 11 Service Assist an ce For profes sional adv ice on generato r set power requireme nts and con scientious servic e, please contact you r nearest K ohler dist ributor or d ealer . • C onsult th e Y ello w Pages under the heading Generators—Elec tric. • Visit t he Kohler Power Sy stems we bsite at KOHLERP o wer [...]

12 Servic e Assistance TP-6843 1/13 Notes[...]

TP-6843 1/13 Section 1 Descriptions and Service Views 13 Section 1 Descriptions and Service Views 1.1 Introduction The generato r set specifi cation s heets provide sp ecific generato r and engine infor mation. Refer to the spec sheet f or data not suppli ed in this manual. Co nsult the generato r set s ervice ma nual, eng ine oper ation manual, an[...]

14 Sect ion 1 Descriptions and Service Views TP-6843 1/ 13 ◦ Back lit display wi th adjustable con trast for excell ent visib ility in all li ghting con diti ons • S crolling system status disp lay ◦ Generato r set st atus ◦ V oltage and pe rcent load ◦ Engi ne tem per atur e ◦ Oil pr essure ◦ Batt ery vo ltage ◦ Engine runtim e hou[...]

TP-6843 1/13 Section 1 Des criptions and Service Views 15 1.7 Service V iews Figure 1-2 Figure 1-2 S ervice View (s ee Figure 1 -3 for opti onal com munications kit compon ents) kps_002.eps ADV-8060 1. Exhaust air outlet 2. Air cleaner 3. Oil fill 4. Oil drain 5. Oil drain valve 6. Oil filter 7. Muffler 8. Alternator air inlet 9. Customer connectio[...]

16 Sect ion 1 Descriptions and Service Views TP-6843 1/ 13 Figure 1-3 Figure 1-3 O ptional C ommunica tions Ki t Componen ts 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 1 2 3 4[...]

TP-6843 1/13 Section 2 Generator Set Operation 17 Section 2 Generator Set Op eration 2.1 Theory of Operation The gene rator set u tilizes a permanen t-magnet alternat or to produc e 3-phase AC v oltage. This voltage i s rect ified using a full -wave 3-ph ase rec tifier (single bl ock rect ifier for 36V and 4 8V , th ree indi vidual rectifi er block[...]

18 Sect ion 2 Generator Set Operation TP- 6843 1/13 Exhaust Sy stem. Check for ex haust leaks a nd blockag es. Chec k the m uffler condi tion. • I nspect the ex haust system co mponents for crac ks, leaks, and cor rosion. Check for tig ht exhaust system conne ction s. • C heck for cor roded or br oken metal parts and repla ce them as ne eded. ?[...]

TP-6843 1/13 Section 2 Generator Set Operation 19 Figure 2-3 Figure 2-3 O utput Block 2.5 Exerci se The VSC contr ollers ca n be set to autom aticall y run the gener ator set at the s ame time a nd day each week. Ex ercising the generato r set weekl y or every two weeks is requi red to ke ep the engi ne and alternat or in goo d operating c onditio [...]

20 Sect ion 2 Generator Set Operation TP- 6843 1/13 2.6.3 Resett ing the Controller Af ter a Fault Shut down Always id entify an d correc t the caus e of a fau lt shutdown b efore reset ting th e controlle r . Check t he fault message displayed on the controll er and refer to Figure 2 -5 to i dentify and correc t the fau lt condi tion before p roce[...]

TP-6843 1/13 Section 2 Generator Set Operation 21 Figure 2-5 Co ntroller Fau lt Messages Enclosure Intrusion Alarm W The enclo sure d oor is ope n. (Option al communi catio ns kit requir ed.) Check for evid ence of un authori zed access t o the gene rator se t. Close and lock the enc losure door. Engine Oil Pressure Lo w SD * The LOP s witch indi c[...]

22 Sect ion 2 Generator Set Operation TP- 6843 1/13 Notes[...]

TP-6843 1/13 Section 3 VSC Controller Operation 23 Section 3 VSC Controller Operation 3.1 VSC Generator Set Controller All 6VSG generato r sets are equipped wit h the VSC generato r set co ntroller . The VSC control s generator set and the optiona l Programma ble Inter face Mod ule (PIM) or Communic ations K it. The VS C controlle r feature s inclu[...]

24 Section 3 VSC Cont roller Operation TP-6843 1/13 3.2.1 Contr oller Keyp ad The RUN, OFF , a nd AUTO buttons c ontrol the generato r set as des cribed in Figure 3-3 . Use the Se lect, Up arro w , and Down a rrow butt ons to navigate through the menus and cha nge sett ings, if necessa ry . See Sect ion 2.4 for operati on instruc tions. 3.2.2 LED I[...]

TP-6843 1/13 Section 3 VSC Controller Operation 25 3.2.3 LCD Dis play The con troller is equipped w ith a two-l ine x 16-charac ter bac klit digital di splay with adjus table contras t. When t he genera tor is ru nning, the control ler automa tically sc rolls through th e display s shown in Figure 3-5. The VSC c ontroller meas ures and display s th[...]

26 Section 3 VSC Cont roller Operation TP-6843 1/13 3.3 Con troller Power The VS C controll er is p owered by th e genera tor set engine s tarting battery and the bui lt-in b attery charge r . Note: T o disc onnect c ontroll er powe r , disc onnect t he AC power to the gener ator se t starting batter y . If control ler power is di sconnected and re[...]

TP-6843 1/13 Section 3 VSC Controller Operation 27 Figure 3-7 Figure 3-7 Changi ng Set tings 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and T ime are used for this example. 3. Press the Select button to enter the Date and Time menu. 4. T o change the da[...]

28 Section 3 VSC Cont roller Operation TP-6843 1/13 3.6 Setting t he Exerciser Set the exercis er to autom aticall y run the generator s et for 20 mi nutes ev ery week or every two weeks. 3.6.1 S ettin g the Exe rciser at Contr oller Power-up When batter y power is conn ected to the c ontroller , you will be p rompted to se t the dat e and time, an[...]

TP-6843 1/13 Section 3 VSC Controller Operation 29 Figure 3-8 Figure 3-8 P rocedure to Set the E xercise r on the VSC Controlle r tp6804 System Voltage: 54.0V Genset - - - - > System Auto Stop Load: (%) Fuel Type: Natual Gas Load Limit: ( %) HOLD: Next Exercise HR:M N PM MM /DD/Y Y HOLD: Exercise Freq: Weekly/ Bi-W eekly Auto Start Volt: (V) Lan[...]

30 Section 3 VSC Cont roller Operation TP-6843 1/13 3.7 VSC Control ler Menus Controll er menus displa y power s ystem infor mation, includi ng status informat ion for the engine, generat or , and optio nal RBUS access ories, ex ercise s ettings, and event history . Some menus al low chang es to the cont roll er se tti ngs. Diagrams in the followi [...]

TP-6843 1/13 Section 3 VSC Controller Operation 31 3.9 Overview Menu Figure 3-10 Figure 3-10 Overview Menu 3.10 Engine Metering Menu The e ngine me tering m enu dis plays e ngine status inform ation as sho wn in Figure 3-1 1. Thi s menu displa ys statu s inf orm ation onl y . No setti ngs can be change d from this menu. Figure 3-11 Figure 3-1 1 Eng[...]

32 Section 3 VSC Cont roller Operation TP-6843 1/13 3.1 1 Generator Metering Menu The gen erator met ering m enu dis plays t he gener ator voltage a nd % load. S ee Figur e 3-12. 3.1 1.1 Ca libration The c alibration mode can b e entered from the Generato r Metering me nu. Contact a Kohler -authori zed dist ributor /dealer f or servi ce. The Re set[...]

TP-6843 1/13 Section 3 VSC Controller Operation 33 3.12 Generator Set Information Menu The gene rator set mo del number and seria l number s are displa yed (see F igure 3-13). N o changes are allowed fr om this men u. Model and serial numbers ar e factory- set and s hould not req uire c hanges in the field , excep t in the event that th e controll [...]

34 Section 3 VSC Cont roller Operation TP-6843 1/13 3.14 Genset System Menu The gens et system menu displays the system info rma tion shown in Figu re 3-19. Gener ato r set s are factory-s et and s hould not req uire ch anges to t he system settings in the fie ld. A Kohl er-auth oriz ed dist rib utor or deal er ca n adju st these settings , if nece[...]

TP-6843 1/13 Section 3 VSC Controller Operation 35 Figure 3-17 Figure 3-17 Effect of Chan ging the Sys tem V oltage S etting Auto St op Load: The auto sto p load is set as a percentage of full load. As the battery bank approac hes the fully charge d state, t he charge rate slows, an d the load on the gene rator set dec reases. The 6V SG will a utom[...]

36 Section 3 VSC Cont roller Operation TP-6843 1/13 3.14. 2 Set ting t he E xerci ser Use the Genset System menus to set th e generato r set e xercise r . See Se ctio n 2.5 fo r instru ctio ns to se t the exer ciser and for more i nformati on about exercis ing the gen erator set. After a scheduled exercise run, the Next Exercise ti me and da te wil[...]

TP-6843 1/13 Section 3 VSC Controller Operation 37 3.15 Date and T ime Menu The date an d time will ty pically be s et at contr oller powerup. T o change the dat e, time, o r time form at (12 hour or 24 hou r), use the Date and Time menu. See Figu re 3- 20. 3.16 Networki ng Information Menus Use the networki ng menus to view and adjust communica ti[...]

38 Section 3 VSC Cont roller Operation TP-6843 1/13 3.16.1 Networking St atus Submenu The Network ing S tatus su bmenu contains settings fo r OnCue ® . See Figur e 3-22. See the OnCue ® Software Operation M anual for information a bout the appropria te network sett ings for O nCue ® . Changes to these se ttings ar e not typi cally required. If D[...]

TP-6843 1/13 Section 3 VSC Controller Operation 39 3.16.2 Networking Configuration Submenu (OnCue ® Password) The networ king Configu ratio n menu incl udes setti ngs used for commun ication with the Kohl er ® OnCue ® Generat or Manageme nt System . See Figu re 3-23. For most a pplicati ons, DHCP is e nabled and the IP settings cannot be changed[...]

40 Section 3 VSC Cont roller Operation TP-6843 1/13 3.16.3 RBUS Information The RBUS Informat ion menu contains se ttings for remote module s that commun icate with the VSC control ler using RBU S protoco l (see Fi gure 3-24). This inc ludes the followin g optional modules : Programma ble Inter face Modu le (PIM) Figure 3-24 Figure 3-24 VSC Info rm[...]

TP-6843 1/13 Section 3 VSC Controller Operation 41 3.16.4 Remote Devi ces Submen u Check the s tatus of remote de vices c ommunic ating through RB US (see Figu re 3-25). D evice types can include : Programma ble Inter face Modu le (PIM) The seria l numbers fo r the PIM are p rinted on the circuit b oards ins ide the enc losures . Figure 3-25 Figure[...]

42 Section 3 VSC Cont roller Operation TP-6843 1/13 3.17 Programmable Int erface Module (PIM) St atus Menu Note: The PIM status men u appears if a program mable i nterface m odule (PIM) o r a commu nicatio ns kit int erface bo ard (IB) i s conne cted. The PIM status menu display s the s tatus of inputs a nd outputs connec ted to the pro grammable i[...]

TP-6843 1/13 Section 3 VSC Controller Operation 43 3.18 Event Log The ev ent log displays up to 10 00 control ler faults a nd notices , starting with the mos t recent event. Events are numbe red 1-1000, w ith 1 being t he most re cent. Each ev ent is displayed with the d ate and time of t he eve nt, t he nu mber of the even t, a code to in dic ate [...]

44 Section 3 VSC Cont roller Operation TP-6843 1/13 Notes[...]

TP-6843 1/13 Section 4 Scheduled Maintenance 45 Section 4 Scheduled Maint enance Disabling the gen erator set. Acciden tal st arting can cause s evere injury or dea th. Before working on the generato r set o r equipme nt co nnected to the set, disable the generato r set a s follo ws: (1) Pre ss the g enerator set OFF/RESET butto n to shut down the [...]

46 Sect ion 4 Scheduled Maintenance TP-6843 1/ 13 4.1.1 Servi ce Schedule, 6VSG Models System Component or Proced ure See Sectio n Procedure Freq uenc y Visually Inspect Check Change Clean Test Fuel Flexible lines and c onnections X R Quarterly Main tank s upply level (if LPG f ueled) X Weekly Fuel piping X Yearly Lubrica tion 4.2 Oil level X X 8 h[...]

TP-6843 1/13 Section 4 Scheduled Maintenance 47 4.2 Lubrication System See th e servic e schedule s in Se ction 4.1 for o il change and oil filter replaceme nt interval s. See the ser vice views i n Sec tion 1.7 for the oil drain, oil dipstick, oi l fill, and oil fi lter lo catio ns. 4.2.1 Low Oil Pres sure Shut down The low oil pr essure (LOP) shu[...]

48 Sect ion 4 Scheduled Maintenance TP-6843 1/ 13 3. Fill with oil. a. Fill the en gine to the F ma rk on the dipsti ck. The en gine oil c apacity is shown in Figure 4-2. See S ection 4.2.3 Engi ne Oil Reco mmendatio n, for oi l select ion. Figure 4-2 Figure 4-2 E ngine Oil Capaci ty b. Reinsta ll the di pstick and the oil fi ll cap. c. Reco nnect [...]

TP-6843 1/13 Section 4 Scheduled Maintenance 49 4.4 Air Cleaner Ser vice The engin e has a replaceab le high-de nsity paper air cleaner element with an o iled foam p reclean er . See Figure 4- 6. Figure 4-6 Figure 4-6 A ir Cleaner Components Check for a b uildup of d irt and deb ris aroun d the air cleaner system. Ke ep this are a clean. Als o chec[...]

50 Sect ion 4 Scheduled Maintenance TP-6843 1/ 13 8. Check the air cleaner bas e. Make su re it is secure and not bent or damag ed. Also che ck the element c over for dam age and fit. Replace all damaged a ir cleaner compone nts. Remove any loose di rt or debri s from the ai r cleaner bas e. Wipe t he base care fully so tha t no di rt dr ops into t[...]

TP-6843 1/13 Section 4 Scheduled Maintenance 51 Refer to this sec tion for gener al battery info rmation and ma intenance . Also consult the batter y manufactu rer ’s instructions for ba ttery maintenan ce. All gen erator set model s use a n egative ground w ith a 12-volt engine el ectrical system. Con sult the generato r set nameplate for the en[...]

52 Sect ion 4 Scheduled Maintenance TP-6843 1/ 13 4.8.5 B attery Perfor m battery s torage la st. 1. Press the OF F button on the gener ator set controlle r . 2. Discon nect the ba ttery , negative ( –) lead fir st. 3. Clean the battery . 4. Place the b attery in a warm, dry l ocation. 5. Connect t he battery to a flo at/equalize battery charge r[...]

TP-6843 1/13 Section 5 Troub leshooting 53 Section 5 Troubleshoo ting 5.1 Introduction Use the tro ubleshootin g charts in t his sectio n to diagnose and co rrect com mon prob lems. F irst ch eck for simpl e cause s such as a de ad eng ine starting battery , loo se conn ections, or an op en circui t breaker . The ch arts include a list of c ommon p[...]

54 Section 5 Troubleshooting TP- 6843 1/13 5.5 T roubleshooting Figure 5-2 contains generato r set trouble shooting, diagnostic, and repair inform ation. Chec k for loose co nnection s before r eplacing parts. Figu re 5- 2 Figure 5-2 G eneral Troubleshoot ing Chart Problem Possible Cause Recommend ed Action Controller displ ay back lig ht is off. B[...]

TP-6843 1/13 Appendix 55 Appendix A Abbrevia tions The foll owing li st contains abbreviati ons that m ay appear in this publicat ion. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital c onverter adj. adjust, adjustment ADV advertising dimensional drawing Ah amp-[...]

56 Appendix TP-6843 1/ 13 kJ kilojoule km kilomet er kOhm, k Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft 3 poun[...]

TP-6843 1/13 Appendix 57 Notes[...]

58 Appendix TP-6843 1/ 13 Notes[...]

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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 installati on, service, and sale s dealer in the US and Canada: Call 1- 800-5 44-2444 or visi t KOHLERPower.com TP-6843 [...]