KOHLER 180REOZJG Industrial Diesel Generator Instructions

KOHLER 180REOZJG Industrial Diesel Generator Instructions

Ratings Range

Generator Set Ratings

| | | | 130 C Rise Standby Rating| **| 105C Rise
Prime Rating| **
---|---|---|---|---|---|---|---
Alternator| Voltage| Ph| Hz| kW/kVA| Amps| kW/kVA| Amps
 | 120/208| 3| 60| 155/190| 538| 140/195| 486
 | 127/220| 3| 60| 160/200| 525| 150/188| 492
 | 120/240| 3| 60| 155/190| 466| 140/195| 421
4S12X| 139/240| 3| 60| 180/225| 541| 165/206| 496
 | 220/380| 3| 60| 140/175| 266| 130/165| 247
 | 277/480| 3| 60| 180/225| 271| 165/206| 248
 | 347/600| 3| 60| 170/210| 204| 155/194| 186
 | 120/208| 3| 60| 180/225| 625| 165/206| 573
 | 127/220| 3| 60| 180/225| 590| 165/206| 541
 | 120/240| 3| 60| 180/225| 541| 165/206| 496
4S13X| 139/240| 3| 60| 180/225| 541| 165/206| 496
 | 220/380| 3| 60| 164/205| 313| 155/194| 294
 | 277/480| 3| 60| 180/225| 271| 165/206| 248
 | 347/600| 3| 60| 180/225| 217| 160/200| 192

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.

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.
• The generator set accepts rated load in one step.
• The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards.
• 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-circuit capability using a rare-earth, permanent magnet (PM)-excited alternator.
  • The brushless, rotating-field alternator has broadrange reconnectability.
• Other features:
  • Kohler designed controllers for one-source system integration and remote communication. See Controllers on page 3.
  • The low coolant level shutdown prevents overheating.
  • Integral vibration isolation eliminates the need for under-unit vibration spring isolators.
• Mount up to three circuit breakers to allow circuit protection of selected priority loads.

Alternator Specifications

Specifications/Alternator

Manufacturer: Kohler
Type: 4-Pole, Rotating-Field
Exciter type: Brushless, Rare-Earth Permanent-Magnet
Leads: quantity, type
4SX: 12, Reconnectable
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, 380 V 4S12X (12 lead): 480 (60 Hz)
480 V, 380 V 4S13X (12 lead): 570 (60 Hz)

• NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting.
• Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds.
• Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the alternator field.
• Self-ventilated and dripproof 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

Engine

Exhaust

Engine Electrical

Fuel

Lubrication

Kohler recommends the use of Kohler Genuine oil and filters.

Cooling

(4850)
Heat rejected to air charge cooler at rated kW, dry exhaust, kW (Btu/min.)| 47.3 (2692)
Water pump type| Centrifugal
Fan diameter, including blades, mm (in.)| 787 (31)
Fan, kWm (HP)| 10.1 (13.5)
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 density = 1.20 kg/m3 (0.075 lbm/ft3)
Fuel Consumption| 60 Hz
---|---
Diesel, Lph (gph) at % load| Standby| Rating
100%| 51.8| (13.7)
75%| 42.7| (11.3)
50%| 28.9| (7.6)
25%| 16.6| (4.4)
Diesel, Lph (gph) at % load| Prime| Rating
100%| 48.4| (12.8)
75%| 39.9| (10.6)
50%| 26.7| (7.0)
25%| 15.3| (4.1)

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, SNMP and 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.

Decision-Maker 6000 Paralleling Controller
Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities for paralleling multiple generator sets.

• 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 Decision-Maker 6000 controllers only

• Digital display and keypad provide easy local data access

• Measurements are selectable in metric or English units

• Remote communication thru a PC via network or modem configuration

• Controller supports Modbus protocol

• Integrated voltage regulator with ±0.25% regulation

• Built-in alternator thermal overload protection

• NFPA 110 Level 1 capability

Refer to G6-107 for additional controller features and accessories.

Modbus is a registered trademark of Schneider Electric.
BACnet is a registered trademark of ASHRAE.

Standard Features

• Alternator Protection
• Battery Rack and Cables
• Customer Connection (standard with Decision-Maker 6000 controller only)
• Local Emergency Stop Switch
• Oil Drain Extension
• Operation and Installation Literature

Available Options

Circuit Breakers

Type/Rating

• Magnetic Trip

• 80%

• Thermal Magnetic Trip

• 100%

• Electronic Trip (LI) Operation

• Electronic Trip with Short Time (LSI)

• Manual

• Electrically Operated (for paralleling)

• Electronic Trip with
  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

•  California OSHPD Pre- Approval

• CSA Certified

• IBC Seismic Certification

• UL 2200 Listing

• Hurricane Rated Enclosure

Enclosed Unit

• Sound Enclosure (with enclosed critical silencer)
• Weather Enclosure (with enclosed critical silencer)

Open Unit

• Exhaust Silencer, Critical (kit: PA-354809)
• Flexible Exhaust Connector, Stainless Steel

Fuel System

• Flexible Fuel Lines
• Fuel Pressure Gauge
• Subbase Fuel Tanks

Controller

• Common Failure Relay (Decision-Maker 6000 and APM603 controllers only)
• Decision-Maker Paralleling System (DPS) (Decision-Maker 6000 controller only)
• Dry Contact (isolated alarm) (Decision-Maker 6000 controller only)
• Two Input/Five Output Module (APM402 controller only)
• Four Input/Fifteen Output Module (APM603 controller only)
• Lockable Emergency Stop Switch
• Remote Emergency Stop Switch
• Remote Serial Annunciator Panel
• Run Relay (standard with APM603, optional with others)
• Manual Key Switch (APM603 controller only)
• Manual Speed Adjust (APM402 controller only)

Cooling System

• Block Heater, 1800 W, 90- 120 V, 1 Ph
• Block Heater, 2000 W, 190- 240 V, 1 Ph Required for ambient temperature below 0°C (32°F)
• Radiator Duct Flange

Electrical System

• Generator Heater
• Battery
• Battery Charger, Equalize/Float Type
• Battery Heater

Miscellaneous

• Air Cleaner, Heavy Duty
• Air Cleaner Restriction Indicator
• Certified Test Report
• Crankcase Emissions Canister
• 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.): 3000 x 1300 x 1668 (118.1 x 51.2 x 65.7)
Weight (radiator model), wet, kg (lb.): 1447 (3190)

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

DISTRIBUTED BY:

2012 Kohler Co. All rights reserved

References

• Kohler Energy | Cleaner Energy Solutions for individuals, businesses and communities

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