KOHLER KG100 Total Energy Systems Instruction Manual

KOHLER KG100 Total Energy Systems

Ratings Range

Standard Features

• Kohler Co. provides one-source responsibility for the generating system and accessories.
• The generator set and its components are prototype-tested, factory-built, and production-tested.
• The 60 Hz generator set offers a UL 2200 listing.
• CSA approval is available.
• The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards.
• The generator set accepts rated load in one step.
• A one-year limited warranty covers all generator set systems and components. Two- and five-year extended limited warranties are also available.
• Alternator features:
• The unique Fast-Response X excitation system delivers excellent voltage response and short-circuits capability using a rare-earth, permanent magnet (PM)-excited alternator.
  • The brushless, rotating-field alternator has a broad range of reconnecting abilities.
• Natural gas, LP gas, and dual fuel models are available.
• Dual fuel model features:
• Natural gas is the primary fuel. Automatically transfers
• Natural gas, LP gas, and dual fuel models are available.
• Dual fuel model features:
• Natural gas is the primary fuel. Automatically transfers back to primary fuel when LPG fuel becomes low or the generator stops and restarts.
  • The patent pending reset box on the generator provides the ability to manually transfer back to natural gas.

Generator Set Ratings

Alternator         Voltage| Ph| Hz| kW/kVA| Amps| kW/kVA| Amps
---|---|---|---|---|---|---
120/208| 3| 60| 100/125| 347| 100/125| 347
127/220| 3| 60| 100/125| 329| 100/125| 329
120/240| 3| 60| 100/125| 301| 100/125| 301
120/240| 1| 60| 91/91| 380| 91/91| 380
139/240| 3| 60| 100/125| 301| 100/125| 301
220/380| 3| 60| 100/125| 190| 100/125| 190
277/480| 3| 60| 100/125| 151| 100/125| 151
4R12X           347/600| 3| 60| 100/125| 121| 100/125| 121
110/190| 3| 50| 76/95| 289| 76/95| 289
115/200| 3| 50| 76/95| 275| 76/95| 275
120/208| 3| 50| 76/95| 264| 76/95| 264
110/220| 3| 50| 76/95| 250| 76/95| 250
110/220| 1| 50| 76/76| 346| 76/76| 346
220/380| 3| 50| 76/95| 145| 76/95| 145
230/400| 3| 50| 76/95| 138| 76/95| 138
240/415| 3| 50| 76/95| 133| 76/95| 133
4T13X           120/240| 1| 60| 100/100| 417| 100/100| 417
110/220| 3| 50| 76/76| 346| 76/76| 346

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. Ratings are in accordance with ISO-8528-1 and ISO-3046-1. 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.

Alternator Specifications

• Manufacturer Kohler

• Type 4-Pole, Rotating-Field

• Exciter type Brushless, Rare- Earth Permanent Magnet

• Leads: quantity, type

  • 4RX 12, Reconnectable
  • 4TX 4, 110- 120/220- 240 V

• Voltage regulator Solid State, Volts/Hz

• Insulation: NEMA MG1
  Material Class H Temperature rise 130C, 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, 400 V 4R9X (12 lead) 385 (60 Hz), 296 (50 Hz)
  • 480 V, 400 V 4R12X (12 lead) 448 (60 Hz), 355 (50 Hz)
  • 240 V, 220 V 4T13X (4 lead) 440 (60 Hz), 396 (50 Hz)

1. NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting.
2. Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds.
3. Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field.
4. Self-ventilated and drip-proof construction.
5. Superior voltage waveform from a two-thirds pitch stator and skewed rotor.
6. Windings are vacuum-impregnated with epoxy varnish for dependability and long life.

Application Data

Engine

Exhaust

• Exhaust System 60 Hz 50 Hz
• Exhaust manifold type Dry
• Exhaust flow at rated kW, m3/min. (cfm) 24 (848) 20 (706)
• Exhaust temperature at rated kW, dry exhaust, C (F) 700 (1292) 650 (1202)
• Maximum allowable back pressure, kPa (in. Hg) 15 (4.43) 12 (3.54)
• Exhaust outlet size at engine hookup, mm (in.)

Engine Electrical

• Engine Electrical System 60 Hz 50 Hz
• Ignition system Coil Pack
• Battery charging alternator: Ground (negative/positive) Negative Volts (DC) 12 Ampere rating 130
• Starter motor rated voltage (DC) 12
• Battery, recommended cold cranking amps (CCA): Qty., rating for – 18C (0°F) One, 650
• Battery voltage (DC) 12

Fuel

Operation Requirements

Controllers

APM402 Controller
Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility.

• Digital display and menu control provide easy local data access
• Measurements are selectable in metric or English units
• Remote communication thru a PC via network or serial configuration
• Controller supports Modbus protocol
• Integrated hybrid voltage regulator with ±0.5% regulation
• Built-in alternator thermal overload protection
• NFPA 110 Level 1 capability
  Refer to G6-161 for additional controller features and accessories.

APM603 Controller
Provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility.

• 7-inch graphic display with touch screen and menu control provides easy local data access

• Measurements are selectable in metric or English units

• Paralleling capability to control up to 8 generators on an isolated bus with first-on logic, synchronizer, kW and kVAR load sharing, and protective relays
  Note: Parallel with other APM603 controllers only

• Generator management to turn paralleled generators off and on
  as required by load demand

• Load management to connect and disconnect loads as required

• Controller supports Modbus RTU, Modbus TCP, SNMPand BACnet

• Integrated voltage regulator with ±0.25% regulation

• Built-in alternator thermal overload protection

• UL-listed overcurrent protective device

• NFPA 110 Level 1 capability
  Refer to G6-162 for additional controller features and accessories.

Standard Features

• Air Cleaner Restrictor Indicator
• Alternator Protection
• Battery Rack and Cables
• Dual Fuel Reset Box (standard on dual fuel models)
• Electronic, Isochronous Governor
• 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)
• Integral Vibration Isolation
• Local Emergency Stop Switch
• Oil Drain Extension
• Operation and Installation Literature
• Open Unit Accessory Kit (radiator duct flange, stone guard, flexible exhaust, and three-way catalyst)
• Three- Way Exhaust Catalyst

Available Options

Circuit Breakers

• Magnetic Trip  80%

• Thermal Magnetic Trip  100%

• Electronic Trip (LI) Operation

• Electronic Trip with
  Short Time (LSI)

• Manual

•  Electrically Operated

• Electronic Trip with (for paralleling)
  Ground Fault (LSIG)
  Circuit Breaker Mounting

• Generator Mounted

• Remote Mounted

• Bus Bar (for remote mounted breakers)
  Enclosures for Remote Mounted Circuit Breakers

• NEMA 1

• NEMA 3R
  Approvals and Listings
  CSA Approval

• IBC Seismic Certification

• UL 2200 Listing

• Hurricane Rated Enclosure
  Enclosure

• Sound Enclosure (with enclosed critical silencer)

• Weather Enclosure (with enclosed critical silencer)
  Open Unit

• Exhaust Silencer, Critical

• Flexible Exhaust Connector, Stainless Steel
  Fuel System

• Dual Fuel NG/LPG (automatic changeover)

• Flexible Fuel Line

• Fuel Filter Kit

• Secondary Gas Solenoid Valve (NFPA Fuel System)
  Controller

• Common Failure Relay (APM603 Controller only)

• Four Input/Fifteen Output Module

• Lockable Emergency Stop

• Manual Key Switch (APM603 only)

• Manual Speed Adjust (APM402 only)

• Remote Emergency Stop

• Run Relay (Standard with APM603)

• Remote Annunciator panel

• Two Input/Five Output Module (APM402 only)
  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

• Battery

• Battery Charger

• Battery Charger Temperature Compensation

• Battery Heater

• Generator Heater
  Miscellaneous

• Certified Test Report

• Engine Fluids Added

• Rated Power Factor Testing

• Rodent Guards
  Literature

• General Maintenance

• NFPA 110

• Overhaul

• Production
  Warranty

• 2-Year Basic Limited Warranty

• 5-Year Basic Limited Warranty

• 5-Year Comprehensive Limited Warranty

Dimensions and Weights

• Overall Size, L x W x H, mm (in.) : 2800 x 1120 x 1528 (110.2 x 44.1 x 60.2)
• Weight, wet, kg (lb.): 1207 (2660)
  NOTE: This drawing is provided for reference only and should not be used for planning installation. Contact your local distributor for more detailed information.

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