Kohler

Standard FeaturesD Kohler Co. provides one-source responsibility for thegenerating 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, whenequipped with the necessary accessories and installed perNFPA standards.

D A one-year limited warranty covers all systems andcomponents. Two- and five-year extended warranties arealso available.

D Alternator features:d The unique Fast-Responset X excitation system deliversexcellent voltage response and short-circuit capabilityusing a rare-earth, permanent magnet (PM)-excitedalternator.

d The brushless, rotating-field alternator has broadrangereconnectability.

D Other features:d Kohler designed controllers for guaranteed systemintegration and remote communication. See Controllerson page 3.

d The electronic, isochronous governor incorporates anintegrated drive-by-wire throttle body actuator deliveringprecise frequency regulation.

Ratings Range60 Hz

Standby: kW 77--100kVA 77--125

Model: 100REZGD

208--600 V Gas

EPA-Certified for StationaryEmergency Applications

G4-204 (100REZGD) 10/13g

Generator Set RatingsNatural Gas LP Gas130_C Rise 130_C Rise

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

4R9X

120/208 3 60 98/123 340 98/123 340127/220 3 60 98/123 321 98/123 321120/240 3 60 98/123 295 98/123 295120/240 1 60 77/77 321 77/77 321139/240 3 60 98/123 295 98/123 295220/380 3 60 98/123 186 98/123 186277/480 3 60 98/123 147 98/123 147347/600 3 60 98/123 118 98/123 118

4R12X

120/208 3 60 100/125 347 100/125 347127/220 3 60 100/125 328 100/125 328120/240 3 60 100/125 301 100/125 301120/240 1 60 91/91 379 91/91 379139/240 3 60 100/125 301 100/125 301220/380 3 60 100/125 190 100/125 190277/480 3 60 100/125 150 100/125 150347/600 3 60 100/125 120 100/125 120

4T13X 120/240 1 60 100/100 417 100/100 417RATINGS: 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 apower 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 forone 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) forratings 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 anyobligation or liability whatsoever. For dual fuel engines, use the LP gas ratings for both the primary and secondary fuels.

G4-204 (100REZGD) 10/13g

Alternator Specifications

Specifications AlternatorManufacturer KohlerType 4-Pole, Rotating-FieldExciter type Brushless, Rare-Earth

Permanent MagnetLeads: quantity, type

4RX 12, Reconnectable4TX 4, 120/240

Voltage regulator Solid State, Volts/HzInsulation: NEMA MG1

Material Class HTemperature rise 130_C, Standby

Bearing: quantity, type 1, SealedCoupling Flexible DiscAmortisseur windings FullVoltage regulation, no-load to full-load Controller DependentOne-step load acceptance 100% of RatingUnbalanced load capability 100% of Rated Standby

Current

Peak motor starting kVA: (35% dip for voltages below)480 V 4R9X (12 lead) 385 (60 Hz)480 V 4R12X (12 lead) 448 (60 Hz)240 V 4T13X (4 lead) 440 (60 Hz)

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

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

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

D Self-ventilated and dripproof construction.

D Vacuum-impregnated windings with fungus-resistant epoxyvarnish for dependability and long life.

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

Application Data

EngineEngine SpecificationsManufacturer General MotorsEngine: model, type Industrial Powertrain

Vortec 5.7 L, 4-CycleTurbocharged

Cylinder arrangement V-8Displacement, L (cu. in.) 5.7 (350)Bore and stroke, mm (in.) 101.6 x 88.4 (4.00 x 3.48)Compression ratio 9.1:1Piston speed, m/min. (ft./min.) 318 (1044)Main bearings: quantity, type 5, M400 Copper LeadRated rpm 1800Max. power at rated rpm, kW (HP) 115 (155)Cylinder head material Cast IronPiston type and material High Silicon AluminumCrankshaft material Nodular IronValve (exhaust) material Forged SteelGovernor type ElectronicFrequency regulation, no-load to full-load IsochronousFrequency regulation, steady state 0.5%Frequency FixedAir cleaner type, all models Dry

ExhaustExhaust SystemExhaust manifold type DryExhaust flow at rated kW, m3/min. (cfm) 24.8 (876)Exhaust temperature at rated kW, dryexhaust, _C (_F) 677 (1250)Maximum allowable back pressure,kPa (in. Hg) 10.2 (3.0)Exhaust outlet size at engine hookup,mm (in.)

Flanged Outlet at Catalystsee ADV drawing

Engine ElectricalEngine Electrical SystemIgnition system Individual Coil

Near Plug Ignition

Battery charging alternator:Ground (negative/positive) NegativeVolts (DC) 12Ampere rating 70

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

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

FuelFuel SystemFuel type Natural Gas, LP Gas, or

Dual FuelFuel supply line inlet 1 1/4 NPTFNatural gas fuel supply pressure, kPa(in. H2O) 1.74--2.74 (7-11)LPG vapor withdrawal fuel supplypressure, kPa (in. H2O) 1.24--2.74 (5-11)Dual fuel engine, LPG vapor withdrawalfuel supply pressure, kPa (in. H2O) 1.24 (5)

Fuel Composition Limits * Nat. Gas LP GasMethane, % 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 isoutside the listed specifications, contact your local distributor forfurther analysis and advice.

G4-204 (100REZGD) 10/13g

Application Data

LubricationLubricating SystemType Full PressureOil pan capacity, L (qt.) 4.7 (5.0)Oil pan capacity with filter, L (qt.) 6.2 (6.5)Oil filter: quantity, type 1, Cartridge

CoolingRadiator SystemAmbient temperature, _C (_F) * 50 (122)Engine jacket water capacity, L (gal.) 6.8 (1.8)Radiator system capacity, includingengine, L (gal.) 22.5 (6.0)Engine jacket water flow, Lpm (gpm) 144 (38)Heat rejected to cooling water at ratedkW, dry exhaust, kW (Btu/min.) 72 (4100)Heat rejected to charge cooling air atrated kW, kW (Btu/min.) 10.5 (600)Water pump type CentrifugalFan diameter, including blades, mm (in.) 660 (26)Fan, kWm (HP) 10.4 (14)Max. restriction of cooling air, intake anddischarge side of radiator, kPa (in. H2O) 0.125 (0.5)* Enclosure with enclosed silencer reduces ambient temperaturecapability by 10_C (18_F).

Operation RequirementsAir Requirements

Radiator-cooled cooling air,m3/min. (scfm)] 198 (7000)Combustion air, m3/min. (cfm) 8.4 (298)Heat rejected to ambient air:

Engine, kW (Btu/min.) 57.4 (3265)Alternator, kW (Btu/min.) 13.7 (780)

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

Fuel Consumption ]

Natural Gas, m3/hr. (cfh) at % load Standby Ratings100% 39.9 (1389)75% 32.1 (1134)50% 24.9 (879)25% 17.7 (624)0% 10.4 (369)

LP Gas, m3/hr. (cfh) at % load Standby Ratings100% 15.2 (538)75% 12.3 (436)50% 9.5 (334)25% 6.6 (232)0% 3.7 (130)

] 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 ControllerProvides advanced control, system monitoring, and system diagnosticsfor optimum performance and compatibility.D Digital display and menu control provide easy local data accessD Measurements are selectable in metric or English unitsD Remote communication thru a PC via network orserial configuration

D Controller supports Modbusr protocolD Integrated hybrid voltage regulator with 0.5% regulationD Built-in alternator thermal overload protectionD NFPA 110 Level 1 capabilityRefer to G6-100 for additional controller features and accessories.

Decision-Makerr 550 ControllerProvides advanced control, system monitoring, and system diagnosticswith remote monitoring capabilities.D Digital display and keypad provide easy local data accessD Measurements are selectable in metric or English unitsD Remote communication thru a PC via network ormodem configuration

D Controller supports Modbusr protocolD Integrated voltage regulator with 0.25% regulationD Built-in alternator thermal overload protectionD NFPA 110 Level 1 capabilityRefer to G6-46 for additional controller features and accessories.

Decision-Makerr 6000 Paralleling ControllerProvides advanced control, system monitoring, and system diagnosticswith remote monitoring capabilities for paralleling multiple generatorsets.D Paralleling capability with first-on logic, synchronizer, kW and kVARload sharing, and protective relays

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

D Controller supports Modbusr protocolD Integrated voltage regulator with 0.25% regulationD Built-in alternator thermal overload protectionD NFPA 110 Level 1 capabilityRefer to G6-107 for additional controller features and accessories.

Overall Size, L x W x H, mm (in.) :2800 x 1120 x 1456 (110.2 x 44.1 x 57.3)

Weight (radiator model), wet, kg (lb.): 1403 (3094)

2011, 2012, 2013 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 planninginstallation. Contact your local distributor for more detailed information.

H

W L

G4-204 (100REZGD) 10/13g

Standard FeaturesD Alternator ProtectionD Battery Rack and CablesD Customer Connection

(Standard with Decision-Makerr 6000 controller only)D Electronic, Isochronous GovernorD Gas Fuel System (includes fuel mixer, electronic secondary gas

regulator, gas solenoid valve, and flexible fuel line between theengine and the skid-mounted fuel system components)

D Integral Vibration IsolationD Local Emergency Stop SwitchD Oil Drain ExtensionD Operation and Installation LiteratureD Three-Way Exhaust Catalyst

Available OptionsApprovals 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-324470)- 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- Secondary Gas Solenoid Valve

Controller- Common Fault Relay- Communication Products and PC Software- Customer Connection (Decision-Makerr 550 controller only)- Dry Contact (isolated alarm)

(Decision-Makerr 550 and 6000 controllers only)- Input/Output Module (Decision-Makerr 3000 controller only)- Remote Annunciator Panel- Remote Audiovisual Alarm Panel

(Decision-Makerr 550 and 6000 controllers only)- Remote Emergency Stop- Run Relay

Cooling System- Block Heater, 1500 W, 110--120 V- Block Heater, 1500 W, 190--240 V

Recommended for ambient temperatures below 10C (50F)

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- Engine Fluids Added- Rated Power Factor Testing- Rodent Guards

Literature- General Maintenance- NFPA 110- Overhaul- Production

Warranty- 2-Year Basic- 5-Year Basic- 5-Year Comprehensive

Other Options- _______________________________________________- _______________________________________________- _______________________________________________- _______________________________________________- _______________________________________________- _______________________________________________- _______________________________________________- _______________________________________________

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

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

Call toll-free in the U.S. and CanadaKOHLER POWERKOHLER, WiSCONSiN 53044

Printed in U.S.A.G12-337 9/10

© 2010 by Kohler Co.

KOHLER® is a registered trademark of Kohler Co. Use of this material for reproduction on the internet and World Wide Web is strictly prohibited without written permission from Kohler Co.

For more information on KOHLER® GAS GENERATORS, call 800-544-2444 or visit KohlerPower.com/Industrial.

MODEL SPECIFICATIONS 25REZG 30REZG 40REZG 45REZG 50REZG 60REZG 80REZG 100REZG 125REZG 150REZG

NG Standby Rating @ 480V (kW/kVA) 25/31 30/38 39/49 42/53 50/63 60/75 81/101 100/125 125/156 150/188

LP Standby Rating @ 480V (kW/kVA) 25/31 31/39 40/50 45/56 52/65 64/80 81/101 100/125 105/131 N/A

Motor Starting @ 35% V Dip (kVA) 121 194 270 515 620

Sound LevelFull Load dBA @ 23 feet 74 74 69 69 68 69 70 71 71 74

Auto-Changeover Dual Fuel ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

NG FUEL CONSUMPTION (STANDBY)

Full Load (cf/h) 366 430 584 584 744 790 1012 1164 1651 1930

75% Load (cf/h) 297 340 486 486 631 685 831 893 1372 1512

50% Load (cf/h) 194 255 360 360 483 520 667 745 984 1112

25% Load (cf/h) 115 179 272 272 333 350 437 466 650 707

LP FUEL CONSUMPTION (STANDBY)

Full Load (cf/h) 156 175 242 246 295 330 425 511 582

N/A75% Load (cf/h) 127 144 191 202 230 250 345 403 469

50% Load (cf/h) 83 108 141 147 178 190 261 306 354

25% Load (cf/h) 50 74 101 104 129 135 177 195 226

MODEL SPECIFICATIONS 180REZX 200REZX 250REZX 300REZX 350REZX 400REZX

NG Standby Rating @ 480V (kW/kVA) 180/225 200/250 260/325 300/375 355/444 400/500

LP Standby Rating @ 480V (kW/kVA) 130/163 130/163 170/213 210/263 240/300 260/325

NG Prime Rating @ 480V (kW/kVA) 164/205 175/219 235/294 270/338 300/375 360/450

Motor Starting @ 35% V Dip (kVA) 790 990 1350 1550

Sound LevelFull Load dBA @ 23 feet 71 71 70 70 70 71

Auto-Changeover Dual Fuel ✓ ✓ ✓ ✓ ✓ ✓

NG FUEL CONSUMPTION (STANDBY)

Full Load (cf/h) 1928 2115 2782 3462 3984 4231

75% Load (cf/h) 1501 1649 2168 2665 3053 3298

50% Load (cf/h) 1067 1158 1521 1875 2109 2317

25% Load (cf/h) 636 706 928 1152 1253 1413

LP FUEL CONSUMPTION (STANDBY)

Full Load (cf/h) 703 703 926 1196 1289 1409

75% Load (cf/h) 600 600 789 861 979 1201

50% Load (cf/h) 406 406 532 640 701 809

25% Load (cf/h) 254 254 335 427 446 512

NG FUEL CONSUMPTION (PRIME)

Full Load (cf/h) 1776 1893 2536 3161 3635 3856

75% Load (cf/h) 1388 1473 1974 2435 2784 3005

50% Load (cf/h) 992 1049 1402 1736 1949 2137

25% Load (cf/h) 579 622 876 1091 1182 1331