KOHLER 30CCL 60 Hz Natural Gas Industrial Gaseous Generators Owner’s Manual

KOHLER 30CCL 60 Hz Natural Gas Industrial Gaseous Generators

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The Kohlerr Advantage

• High-Quality Power
  Kohler generators provide advanced voltage and frequency regulation along with ultra-low levels of harmonic distortion for excellent generator power quality to protect your valuable electronics.

• Extraordinary Reliability
  Kohler is known for extraordinary reliability and performance and backs that up with a premium five-year or 2000-hour limited warranty.

•  All-Aluminum Sound Enclosure
  Durable aluminum sound-attenuating enclosure.

Generator Set Ratings

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 rating guidelines, complete rating 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. G4-275 (30CCL) 7/21c

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 generator set accepts the rated load in one step.
•  A five-year/2000-hour limited warranty covers all generator set systems and components. A five-year extended comprehensive limited warranty is also available.
•  Engine Features
•  Powerful and reliable 2.2 L turbocharged liquid-cooled engine
•  Electronic engine management system.
•  Simple field conversion between natural gas and LPG fuels while maintaining emission certification.
•  Innovative Cooling System
•  Electronically controlled fan speeds minimize generator set sound signature.
•  Alternator features:
  •  Kohler’s wound field excitation system with its unique PowerBoostt design delivers great voltage response and short-circuit capability.
  •  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.
  •  Kohler designed a controller for one-source system integration and remote communication. See Controller on page 3.
•  Certifications
• The generator set engine is certified by the Environmental Protection Agency (EPA) to conform to the New Source Performance Standard (NSPS) for stationary spark-ignited emissions.
•  UL 2200/cUL listing is available.
•  The generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards.
• CSA certification is available.
•  Accepted by the Massachusetts Board of Registration of Plumbers and Gas Fitters.
•  Approved for stationary standby applications in locations served by a reliable utility source.

Alternator Specifications

•  NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting.
•  Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field.
•  Self-ventilated and drip-proof construction.
•  Windings are vacuum-impregnated with epoxy varnish for dependability and long life.
•  Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

Application Data

• Manufacturer Kohler
• Engine: model, type KG2204T, 2.2 L, 4-Cycle
• Turbocharged
• Cylinder arrangement In-line 4
• Displacement, L (cu. in.) 2.2 (134.25)
• Bore and stroke, mm (in.) 91 x 86 (3.5 x 3.4)
• Compression ratio 10.5:1
• Piston speed, m/min. (ft./min.) 340 (1016)
• Main bearings: quantity, type 5, plain alloy steel
• Rated rpm 1800
• Max power at rated RPM, kW (HP)
• LPG 47.8 (64.1)
• Natural Gas 47.6 (63.9)
• 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 1.0%
• Frequency Fixed
• Air cleaner type, all models Dry

Engine Electrical

• Ignition system Electronic
• Battery charging alternator:
• Ground (negative/positive) Negative
• Volts (DC) 14
• Ampere rating 90
• Starter motor rated voltage (DC) 12
• Battery recommended cold cranking
• amps (CCA):
• Qty., rating for – 18_C (0F) One, 630
• Battery voltage (DC) 12
• Battery group size 24

Exhaust

• Exhaust manifold type Dry
• Exhaust temperature at rated kW, dry
• exhaust, _C (_F) 610 (1130)
• Maximum allowable back pressure,
• kPa (in. Hg) 7.5 (2.2)

Fuel

• Fuel type Natural Gas or LPG
• Fuel supply line inlet 1 NPTF
• Natural gas fuel supply pressure, a
• (in. H2O) 1.2- 2.7 (5-11)
• LPG vapor withdrawal fuel supply
• pressure, kPa (in. H2O) 1.2- 2.7 (5-11)

*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.

Lubrication

• Type Full Pressure
• Oil pan capacity, L (qt.) w 4.2 (4.4)
• Oil added during an oil change (on
• average), L (qt.) w 3.3 (3.5)
• Oil pan capacity with filter, L (qt.) w 8.5 (9.0)
• Oil filter: quantity, type w 1, Cartridge
• Kohler recommends the use of Kohler Genuine oil and filters.

Cooling

• Ambient temperature, _C (_F) 50 (122)
• Engine jacket water capacity, L (gal.) 2.65 (0.7)
• Radiator system capacity, including
• engine, L (gal.) 13.2 (3.5)
• Engine jacket water flow, Lpm (GPM) 62 (16.4)
• Heat rejected to cooling water at rated
• kW, dry exhaust, kW (Btu/min.) 22.5 (1280)
• Water pump-type Centrifugal
• Fan diameter, including blades, mm (in.) qty. 3 @ 406 (16)
• Fan power requirements (powered by
• engine battery charging alternator) 12 VDC, 18 amps each

Operation Requirements

• Radiator-cooled cooling air,
• m3/min. (scfm)] 51 (1800)
• Combustion air, m3/min. (cfm) 1.6 (57)
• Air over engine m3/min. (cfm) 25 (883)
• [ Air density = 1.20 kg/m3 (0.075 lb/ft3)

Fuel Consumption

• 100% 11.9 (421)
• 75% 10.0 (355)
• 50% 8.2 (289)
• 25% 6.3 (223)
• 0% 4.5 (158)

LP Gas, m3/hr. (cfh) at % load Standby Ratings

• 100% 4.6 (164)
• 75% 3.7 (131)
• 50% 2.8 (99)
• 25% 1.9 (66)
• 0% 1.0 (34)

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.

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
•  The controller supports the 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.
• Modbus is a registered trademark of Schneider Electric.

Sound Enclosure

•  Durable aluminum, sound-attenuating enclosure with the quiet operation of 57 dB(A) log average @ 7 m (23 ft.) at no load.
•  Internally mounted silencer.
•  Fade-, scratch and corrosion-resistant Kohler Power Armor automotive-grade textured finish.
•  Acoustic insulation that meets UL 94 HF1 flammability classification and repels moisture absorption.

Standard Features

•  Alternator Protection
•  Aluminum Sound Enclosure with Enclosed Silencer
•  Battery Rack and Cables
•  Flexible Fuel Line
•  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
•  Low Fuel Pressure Switch (with NFPA fuel module) D Oil Drain Extension
•  Operation and Installation Literature
•  Standard 5-Year Limited Warranty

Available Options

•  CSA Certified
•  UL 2200 Listing
• Controller
•  15-Relay Dry Contact Board
•  Communication Products
•  Input/Output Module (2 inputs, 5 outputs)
•  Lockable Emergency Stop (lockout / Tagout)
•  Manual Key Switch
•  Manual Speed Adjust
•  Remote Annunciator Panel
•  Remote Emergency Stop
•  Run Relay
• enclosure Accessories
•  Enclosure Doors for 291 kph (181 mph) Wind Load Starting Aids*
•  Block Heater, 110- 120 V
•  Block Heater, 220- 240 V
• oil Pan Heater*
•  Oil Pan Heater, 110- 120 V
•  Oil Pan Heater, 190- 240 V

Electrical System

•  Alternator Strip Heater
•  Battery
•  Battery Charger, 6 Amp
•  Battery Charger, 10 Amp w/Alarms
•  Battery Heater
•  Temperature Compensation for 10 Amp Battery Charger

Miscellaneous

•  Air Cleaner Restriction Indicator
•  Certified Test Report
•  Engine Fluids Added
•  Maintenance Kit (filters, spark plugs, oil)
•  Rated Power Factor Testing
• Literature
•  General Maintenance
•  NFPA 110
•  Overhaul
•  Production
• Warranty
•  Extended 5-Year/2000-Hour Comprehensive Limited Warranty Other Options
•  ___
•  ___
•  ___
•  ___
•  ___
•  ___
•  ___
•  ___

Dimensions and Weights

• Overall Size, L x W x H, mm (in.): 2280 x 830 x 1182 (89.8 x 32.7 x 46.5)
• Weight, with engine fluids, kg (lb.): 635 (1432)

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

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