Amendment 1 - 40REZG.pdf

Standard Features D Kohler Co. provides one-source responsibility for the generating system and accessories.

D The generator set and its components are prototype-tested, factory-built, and production-tested.

D The 60 Hz generator set offers a UL 2200 listing.

D The generator set accepts rated load in one step.

D The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards.

D A one-year limited warranty covers all generator set systems and components. Two- and five-year extended limited warranties are also available.

D Alternator features:

d The unique Fast-Responser II excitation system delivers excellent voltage response and short-circuit capability using a permanent magnet (PM)-excited alternator.

d The brushless, rotating-field alternator has broadrange reconnectability.

D Other features:

d Kohler designed controllers for guaranteed system integration and remote communication. See Controllers on page 3.

d The electronic, isochronous governor incorporates an integrated drive-by-wire throttle body actuator delivering precise frequency regulation.

Ratings Range 60 Hz 50 Hz

Standby: kW 33--40 24--34 kVA 33--50 26--40

Model: 40REZG 190--600 V Gas

EPA-Certified for Stationary Emergency Applications

G4-139 (40REZG) 4/15j

Generator Set Ratings Natural Gas LP Gas 130_C Rise 130_C Rise

Standby Rating Standby Rating Alternator Voltage Ph Hz kW/kVA Amps kW/kVA Amps

4P5

120/208 3 60 39/49 135 39/49 135 127/220 3 60 39/49 128 40/50 131 120/240 3 60 39/49 117 39/49 117 120/240 1 60 33/33 138 33/33 138 139/240 3 60 39/49 117 40/50 120 220/380 3 60 35/44 66 35/44 66 277/480 3 60 39/49 58 40/50 60 347/600 3 60 39/49 47 40/50 48 110/190 3 50 31/39 119 32/40 122 115/200 3 50 28/35 101 28/35 101 120/208 3 50 24/30 83 24/30 83 110/220 3 50 31/39 102 32/40 105 110/220 1 50 26/26 118 26/26 118 220/380 3 50 31/39 59 32/40 61 230/400 3 50 28/35 51 28/35 51 240/416 3 50 24/30 42 24/30 42

4Q5 120/240 1 60 38/38 158 38/38 158 110/220 1 50 30/30 136 32/32 145

4Q7 120/240 1 60 40/40 167 40/40 167 110/220 1 50 32/32 145 34/34 155

RATINGS: All three-phase units are rated at 0.8 power factor. All single-phase units are rated at 1.0 power factor. Standby Ratings: The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for this rating. Prime Power Ratings: At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is available for one hour in twelve. Ratings are in accordance with ISO-8528-1 and ISO-3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical information bulletin (TIB-101) for ratings guidelines, complete ratings definitions, and site condition derates. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. For dual fuel engines, use the natural gas ratings for both the primary and secondary fuels.

G4-139 (40REZG) 4/15j

Alternator Specifications

Specifications Alternator Manufacturer Kohler Type 4-Pole, Rotating-Field Exciter type Brushless, Permanent-

Magnet Leads: quantity, type

4P5 12, Reconnectable 4Q5, 4Q7 4, 110--120/220--240

Voltage regulator Solid State, Volts/Hz Insulation: NEMA MG1

Material Class H Temperature rise 130_C, Standby

Bearing: quantity, type 1, Sealed Coupling Flexible Disc Amortisseur windings Full Voltage regulation, no-load to full-load Controller Dependent One-step load acceptance 100% of Rating Unbalanced load capability 100% of Rated Standby

Current

Peak motor starting kVA: (35% dip for voltages below) 480 V, 380 V 4P5 (12 lead) 140 (60 Hz), 98 (50 Hz) 240 V, 220 V 4Q5 (4 lead) 95 (60 Hz), 78 (50 Hz) 240 V, 220 V 4Q7 (4 lead) 104 (60 Hz), 91 (50 Hz)

D NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting.

D Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds.

D Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field.

D Self-ventilated and dripproof construction.

D Windings are vacuum-impregnated with epoxy varnish for dependability and long life.

D Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

D Fast-Responser II brushless alternator with brushless exciter for excellent load response.

Application Data

Engine Engine Specifications 60 Hz 50 Hz Manufacturer General Motors Engine: model, type Industrial Powertrain

Vortec 4.3 L, 4-Cycle Natural Aspiration

Cylinder arrangement V-6 Displacement, L (cu. in.) 4.3 (262) Bore and stroke, mm (in.) 101.6 x 88.4 (4.00 x 3.48) Compression ratio 9.05:1 Piston speed, m/min. (ft./min.) 318 (1044) 265 (870) Main bearings: quantity, type 4, Babbitt Rated rpm 1800 1500 Max. power at rated rpm, kW (HP) 54 (72) 45 (60) Engine power at standby rating, kW (HP)

Natural Gas 41.9 (56) 40.3 (54) LP Gas 45.3 (61) 42.5 (57)

Cylinder head material Cast Iron Piston type and material High Silicon Aluminum Crankshaft material Nodular Iron Valve (exhaust) material Forged Steel Governor type Electronic Frequency regulation, no-load to full-load Isochronous Frequency regulation, steady state 0.5% Frequency Fixed Air cleaner type, all models Dry

Exhaust Exhaust System 60 Hz 50 Hz Exhaust manifold type Dry Exhaust flow at rated kW, m3/min. (cfm) 8.8 (310) 7.4 (260) Exhaust temperature at rated kW, dry exhaust, _C (_F) 649 (1200) Maximum allowable back pressure, kPa (in. Hg) 10.2 (3.0) Exhaust outlet size at engine hookup, mm (in.) 76 (3.0) OD

Engine Electrical Engine Electrical System 60 Hz 50 Hz Ignition system Electronic, Distributor Battery charging alternator:

Ground (negative/positive) Negative Volts (DC) 12 Ampere rating 70

Starter motor rated voltage (DC) 12 Battery, recommended cold cranking amps (CCA):

Qty., rating for --18_C (0F) 1, 630 Battery voltage (DC) 12

Fuel Fuel System 60 Hz 50 Hz Fuel type Natural Gas, LP Gas, or

Dual Fuel Fuel supply line inlet 1 NPTF Natural gas fuel supply pressure, kPa

(in. H2O) 1.74--2.74 (7-11) LPG vapor withdrawal fuel supply pressure, kPa (in. H2O) 1.24--2.74 (5-11) Dual fuel engine, LPG vapor withdrawal fuel supply pressure, kPa (in. H2O) 1.24 (5)

Fuel Composition Limits * Nat. Gas LP Gas Methane, % by volume 90 min. — Ethane, % by volume 4.0 max. — Propane, % by volume 1.0 max. 85 min.

Propene, % by volume 0.1 max. 5.0 max.

C4 and higher, % by volume 0.3 max. 2.5 max.

Sulfur, ppm mass 25 max.

Lower heating value, MJ/m3 (Btu/ft3), min. 33.2 (890) 84.2 (2260)

* Fuels with other compositions may be acceptable. If your fuel is outside the listed specifications, contact your local distributor for further analysis and advice.

G4-139 (40REZG) 4/15j

Application Data

Lubrication Lubricating System 60 Hz 50 Hz Type Full Pressure Oil pan capacity, L (qt.) 4.3 (4.5) Oil pan capacity with filter, L (qt.) 5.7 (6.0) Oil filter: quantity, type 1, Cartridge

Cooling Radiator System 60 Hz 50 Hz Ambient temperature, _C (_F) * 50 (122) Engine jacket water capacity, L (gal.) 6.8 (1.8) Radiator system capacity, including engine, L (gal.) 19.7 (5.2) Engine jacket water flow, Lpm (gpm) 106.0 (28) 87.1 (23) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 39.2 (2230) 34.6 (1970) Water pump type Centrifugal Fan diameter, including blades, mm (in.) 533 (21) Fan, kWm (HP) 1.5 (2.0) 1.0 (1.2) Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H2O) 0.125 (0.5)

* Enclosure with enclosed silencer reduces ambient temperature capability by 5_C (9_F).

Operation Requirements Air Requirements 60 Hz 50 Hz Radiator-cooled cooling air, m3/min. (scfm) [ 142 (5000) 113 (4000) Combustion air, m3/min. (cfm) 2.61 (92) 2.20 (78) Heat rejected to ambient air:

Engine, kW (Btu/min.) 16.0 (910) 15.4 (860) Alternator, kW (Btu/min.) 6.3 (360) 6.2 (350)

[ Air density = 1.20 kg/m3 (0.075 lbm/ft3)

Fuel Consumption ] 60 Hz 50 Hz

Natural Gas, m3/hr. (cfh) at % load Standby Ratings 100% 16.5 (584) 13.5 (477) 75% 13.8 (486) 10.4 (367) 50% 10.2 (360) 8.0 (281) 25% 7.7 (272) 5.8 (206)

LP Gas, m3/hr. (cfh) at % load Standby Ratings 100% 6.9 (242) 5.4 (190) 75% 5.4 (191) 4.2 (148) 50% 4.0 (141) 3.1 (111) 25% 2.9 (101) 2.3 (81)

] Nominal fuel rating: Natural gas, 37 MJ/m3 (1000 Btu/ft.3) LP vapor, 93 MJ/m3 (2500 Btu/ft.3)

LP vapor conversion factors:

8.58 ft.3 = 1 lb.

0.535 m3 = 1 kg.

36.39 ft.3 = 1 gal.

Controllers

Decision-Makerr 3000 Controller Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility.

D Digital display and menu control provide easy local data access D Measurements are selectable in metric or English units D Remote communication thru a PC via network or serial configuration

D Controller supports Modbusr protocol D Integrated hybrid voltage regulator with 0.5% regulation D Built-in alternator thermal overload protection D NFPA 110 Level 1 capability Refer to G6-100 for additional controller features and accessories.

Decision-Makerr 550 Controller Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities.

D Digital display and keypad provide easy local data access D Measurements are selectable in metric or English units D Remote communication thru a PC via network or modem configuration

D Controller supports Modbusr protocol D Integrated voltage regulator with 0.25% regulation D Built-in alternator thermal overload protection D NFPA 110 Level 1 capability Refer to G6-46 for additional controller features and accessories.

Modbusr is a registered trademark of Schneider Electric.

Overall Size, L x W x H, mm (in.):

Wide Skid 2200 x 1040 x 1172 (86.6 x 40.9 x 46.1) Narrow Skid 2200 x 864 x 1172 (86.6 x 34.0 x 46.1)

Weight (radiator model), wet, kg (lb.): 556 (1225)

2009, 2010, 2011, 2012, 2013, 2014, 2015 by Kohler Co. All rights reserved.

DISTRIBUTED BY:

Dimensions and Weights

NOTE: This drawing is provided for reference only and should not be used for planning installation. Contact your local distributor for more detailed information.

H

W L

G4-139 (40REZG) 4/15j

Standard Features D Alternator Protection D Battery Rack and Cables D Electronic, Isochronous Governor D Gas Fuel System (includes fuel mixer, electronic secondary gas regulator, gas solenoid valve, and flexible fuel line between the engine and the skid-mounted fuel system components)

D Integral Vibration Isolation D Local Emergency Stop Switch D Oil Drain Extension D Operation and Installation Literature

Available Options Approvals and Listings

- CSA Approval

- IBC Seismic Certification

- UL 2200 Listing

Enclosed Unit

- Sound Enclosure (with enclosed critical silencer)

- Weather Enclosure (with enclosed critical silencer)

Open Unit

- Exhaust Silencer, Critical (kit: PA-352663)

- Flexible Exhaust Connector, Stainless Steel

Fuel System

- Dual Fuel NG/LPG (automatic changeover)

- Flexible Fuel Line

(required when the generator set skid is spring mounted)

- Gas Filter

- LP Liquid Wtihdrawal (vaporizer)

- Secondary Gas Solenoid Valve

Controller

- Common Fault Relay

- Communication Products and PC Software

(Decision-Makerr 550 controller only)

- Customer Connection

(Decision-Makerr 550 controller only)

- Dry Contact (isolated alarm)

(Decision-Makerr 550 controller only)

- Input/Output Module

(Decision-Makerr 3000 controller only)

- Remote Annunciator Panel

- Remote Audiovisual Alarm Panel

(Decision-Makerr 550 controller only)

- Remote Emergency Stop

- Run Relay

Cooling System

- Block Heater, 1000 W, 110--120 V

Recommended for ambient temperatures below 10C (50F)

- Radiator Duct Flange

Electrical System

- Alternator Strip Heater

- Battery

- Battery Charger, Equalize/Float Type

- Battery Heater

- Line Circuit Breaker (NEMA1 enclosure)

- Line Circuit Breaker with Shunt Trip (NEMA1 enclosure)

Miscellaneous

- Air Cleaner Restrictor Indicator

- Certified Test Report

- Engine Fluids (oil and coolant) Added

- Rated Power Factor Testing

- Rodent Guards

Literature

- General Maintenance

- NFPA 110

- Overhaul

- Production

Warranty

- 2-Year Basic Limited

- 5-Year Basic Limited

- 5-Year Comprehensive Limited

Other Options

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455

KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-457-4441, Fax 920-459-1646 For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com