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Manual Kohler 36VDC

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  • Kohler 36VDC - page 1

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

  • Kohler 36VDC - page 2

    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 ...

  • Kohler 36VDC - page 3

    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 . . . . . . ...

  • Kohler 36VDC - page 4

    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 ...

  • Kohler 36VDC - page 5

    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 ...

  • Kohler 36VDC - page 6

    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 ...

  • Kohler 36VDC - page 7

    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 ...

  • Kohler 36VDC - page 8

    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 ...

  • Kohler 36VDC - page 9

    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 , ...

  • Kohler 36VDC - page 10

    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 ...

  • Kohler 36VDC - page 11

    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 ...

  • Kohler 36VDC - page 12

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

  • Kohler 36VDC - page 13

    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 ...

  • Kohler 36VDC - page 14

    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 ...

  • Kohler 36VDC - page 15

    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 ...

  • Kohler 36VDC - page 16

    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 ...

  • Kohler 36VDC - page 17

    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 ...

  • Kohler 36VDC - page 18

    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. ? ...

  • Kohler 36VDC - page 19

    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 ...

  • Kohler 36VDC - page 20

    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 ...

  • Kohler 36VDC - page 21

    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 ...

  • Kohler 36VDC - page 22

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

  • Kohler 36VDC - page 23

    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 ...

  • Kohler 36VDC - page 24

    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 ...

  • Kohler 36VDC - page 25

    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 ...

  • Kohler 36VDC - page 26

    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 ...

  • Kohler 36VDC - page 27

    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 ...

  • Kohler 36VDC - page 28

    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 ...

  • Kohler 36VDC - page 29

    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 ...

  • Kohler 36VDC - page 30

    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 ...

  • Kohler 36VDC - page 31

    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 ...

  • Kohler 36VDC - page 32

    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 ...

  • Kohler 36VDC - page 33

    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 ...

  • Kohler 36VDC - page 34

    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 ...

  • Kohler 36VDC - page 35

    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 ...

  • Kohler 36VDC - page 36

    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 ...

  • Kohler 36VDC - page 37

    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 ...

  • Kohler 36VDC - page 38

    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 ...

  • Kohler 36VDC - page 39

    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 ...

  • Kohler 36VDC - page 40

    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 ...

  • Kohler 36VDC - page 41

    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 ...

  • Kohler 36VDC - page 42

    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 ...

  • Kohler 36VDC - page 43

    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 ...

  • Kohler 36VDC - page 44

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

  • Kohler 36VDC - page 45

    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 ...

  • Kohler 36VDC - page 46

    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 ...

  • Kohler 36VDC - page 47

    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 ...

  • Kohler 36VDC - page 48

    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 ...

  • Kohler 36VDC - page 49

    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 ...

  • Kohler 36VDC - page 50

    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 ...

  • Kohler 36VDC - page 51

    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 ...

  • Kohler 36VDC - page 52

    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 ...

  • Kohler 36VDC - page 53

    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 ...

  • Kohler 36VDC - page 54

    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 ...

  • Kohler 36VDC - page 55

    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- ...

  • Kohler 36VDC - page 56

    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 ...

  • Kohler 36VDC - page 57

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

  • Kohler 36VDC - page 58

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

  • Kohler 36VDC - page 59

    ...

  • Kohler 36VDC - page 60

    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 ...

Manufacturer Kohler Category Portable Generator

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Kohler 36VDC by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Kohler 36VDC.

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5. FAQ - Frequently Asked Questions
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