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Model:

100REZGD
Gas

208-600 V EPA-Certified for Stationary Emergency Applications

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 systems and components. Two- and five-year extended warranties are also available. D Alternator features: d The unique Fast-Responset X excitation system delivers excellent voltage response and short-circuit capability using a rare-earth, 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
Standby: kW kVA

60 Hz 77--100 77--125

Generator Set Ratings


Alternator Voltage 120/208 127/220 120/240 120/240 139/240 220/380 277/480 347/600 120/208 127/220 120/240 120/240 139/240 220/380 277/480 347/600 120/240 Ph 3 3 3 1 3 3 3 3 3 3 3 1 3 3 3 3 1 Hz 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 Natural Gas 130_C Rise Standby Rating kW/kVA Amps 98/123 340 98/123 321 98/123 295 77/77 321 98/123 295 98/123 186 98/123 147 98/123 118 100/125 347 100/125 328 100/125 301 91/91 379 100/125 301 100/125 190 100/125 150 100/125 120 100/100 417 LP Gas 130_C Rise Standby Rating kW/kVA Amps 98/123 340 98/123 321 98/123 295 77/77 321 98/123 295 98/123 186 98/123 147 98/123 118 100/125 347 100/125 328 100/125 301 91/91 379 100/125 301 100/125 190 100/125 150 100/125 120 100/100 417

4R9X

4R12X

4T13X

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 LP gas ratings for both the primary and secondary fuels. G4-204 (100REZGD) 10/13g

Alternator Specifications
Specifications Manufacturer Type Exciter type Leads: quantity, type 4RX 4TX Voltage regulator Insulation: Material Temperature rise Bearing: quantity, type Coupling Amortisseur windings Voltage regulation, no-load to full-load One-step load acceptance Unbalanced load capability Peak motor starting kVA: 480 V 4R9X (12 lead) 480 V 4R12X (12 lead) 240 V 4T13X (4 lead) Alternator Kohler 4-Pole, Rotating-Field Brushless, Rare-Earth Permanent Magnet 12, Reconnectable 4, 120/240 Solid State, Volts/Hz NEMA MG1 Class H 130_C, Standby 1, Sealed Flexible Disc Full Controller Dependent 100% of Rating 100% of Rated Standby Current (35% dip for voltages below) 385 (60 Hz) 448 (60 Hz) 440 (60 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 Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life. D Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

Application Data
Engine
Engine Specifications Manufacturer Engine: model, type Cylinder arrangement Displacement, L (cu. in.) Bore and stroke, mm (in.) Compression ratio Piston speed, m/min. (ft./min.) Main bearings: quantity, type Rated rpm Max. power at rated rpm, kW (HP) Cylinder head material Piston type and material Crankshaft material Valve (exhaust) material Governor type Frequency regulation, no-load to full-load Frequency regulation, steady state Frequency Air cleaner type, all models General Motors Industrial Powertrain Vortec 5.7 L, 4-Cycle Turbocharged V-8 5.7 (350) 101.6 x 88.4 (4.00 x 3.48) 9.1:1 318 (1044) 5, M400 Copper Lead 1800 115 (155) Cast Iron High Silicon Aluminum Nodular Iron Forged Steel Electronic Isochronous 0.5% Fixed Dry

Engine Electrical
Engine Electrical System Ignition system Battery charging alternator: Ground (negative/positive) Volts (DC) Ampere rating Starter motor rated voltage (DC) Battery, recommended cold cranking amps (CCA): Qty., rating for --18_C (0F) Battery voltage (DC) Individual Coil Near Plug Ignition Negative 12 70 12

1, 630 12

Fuel
Fuel System Fuel type Fuel supply line inlet Natural gas fuel supply pressure, kPa (in. H2O) LPG vapor withdrawal fuel supply pressure, kPa (in. H2O) Dual fuel engine, LPG vapor withdrawal fuel supply pressure, kPa (in. H2O) Fuel Composition Limits * Methane, % by volume Ethane, % by volume Propane, % by volume Propene, % by volume C4 and higher, % by volume Sulfur, ppm mass Lower heating value, MJ/m3 (Btu/ft3), min. Natural Gas, LP Gas, or Dual Fuel 1 1/4 NPTF 1.74--2.74 (7-11) 1.24--2.74 (5-11) 1.24 (5) Nat. Gas LP Gas 90 min. 4.0 max. 1.0 max. 85 min. 0.1 max. 5.0 max. 0.3 max. 2.5 max. 25 max. 33.2 (890) 84.2 (2260)

Exhaust
Exhaust System Exhaust manifold type Exhaust flow at rated kW, m3/min. (cfm) Exhaust temperature at rated kW, dry exhaust, _C (_F) Maximum allowable back pressure, kPa (in. Hg) Exhaust outlet size at engine hookup, mm (in.) Dry 24.8 (876) 677 (1250) 10.2 (3.0) Flanged Outlet at Catalyst see ADV drawing

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

G4-204 (100REZGD) 10/13g

Application Data
Lubrication
Lubricating System Type Oil pan capacity, L (qt.) Oil pan capacity with filter, L (qt.) Oil filter: quantity, type Full Pressure 4.7 (5.0) 6.2 (6.5) 1, Cartridge 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.

Controllers

Cooling
Radiator System 50 (122) Ambient temperature, _C (_F) * Engine jacket water capacity, L (gal.) 6.8 (1.8) Radiator system capacity, including engine, L (gal.) 22.5 (6.0) Engine jacket water flow, Lpm (gpm) 144 (38) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 72 (4100) Heat rejected to charge cooling air at rated kW, kW (Btu/min.) 10.5 (600) Water pump type Centrifugal Fan diameter, including blades, mm (in.) 660 (26) Fan, kWm (HP) 10.4 (14) 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 10_C (18_F).

Operation Requirements
Air Requirements Radiator-cooled cooling air, m3/min. (scfm)] Combustion air, m3/min. (cfm) Heat rejected to ambient air: Engine, kW (Btu/min.) Alternator, kW (Btu/min.) [ Air density = 1.20 kg/m3 (0.075 lbm/ft3) Fuel Consumption ] Natural Gas, m3/hr. (cfh) at % load 100% 75% 50% 25% 0% LP Gas, m3/hr. (cfh) at % load 100% 75% 50% 25% 0% ] Nominal fuel rating: Standby Ratings 39.9 (1389) 32.1 (1134) 24.9 (879) 17.7 (624) 10.4 (369) Standby Ratings 15.2 (538) 12.3 (436) 9.5 (334) 6.6 (232) 3.7 (130) 198 (7000) 8.4 (298) 57.4 (3265) 13.7 (780)

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.

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.

Decision-Makerr 6000 Paralleling Controller Provides advanced control, system monitoring, and system diagnostics with remote monitoring capabilities for paralleling multiple generator sets. D Paralleling capability with first-on logic, synchronizer, kW and kVAR load sharing, and protective relays 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 G6-107 for additional controller features and accessories.

G4-204 (100REZGD) 10/13g

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

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 Miscellaneous Air Cleaner Restrictor Indicator Engine Fluids Added Rated Power Factor Testing Rodent Guards Literature General Maintenance NFPA 110 Overhaul Production

Standard Features
D Alternator Protection D Battery Rack and Cables D Customer Connection (Standard with Decision-Makerr 6000 controller only) 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 D Three-Way Exhaust Catalyst
   

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-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

Warranty - 2-Year Basic - 5-Year Basic  5-Year Comprehensive Other Options _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________ _______________________________________________

Dimensions and Weights


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)

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)

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: Still water refrigration

2011, 2012, 2013 by Kohler Co. All rights reserved. G4-204 (100REZGD) 10/13g

MODEL SPECIFICATIONS NG Standby Rating @ 480V (kW/kVA) LP Standby Rating @ 480V (kW/kVA) Motor Starting @ 35% V Dip (kVA) Sound Level Full Load dBA @ 23 feet Auto-Changeover Dual Fuel Full Load (cf/h) 75% Load (cf/h) 50% Load (cf/h) 25% Load (cf/h) Full Load (cf/h) 75% Load (cf/h) 50% Load (cf/h) 25% Load (cf/h)

25REZG 25/31 25/31 121 74

30REZG 30/38 31/39

40REZG 39/49 40/50

45REZG 42/53 45/56

50REZG 50/63 52/65

60REZG 60/75 64/80

80REZG 81/101 81/101

100REZG 125REZG 150REZG 100/125 100/125 125/156 105/131 150/188 N/A 620 71 74

194 74 69 69 68 69

270 70 71

515

NG FUEL CONSUMPTION (STANDBY) 366 297 194 115 156 127 83 50 430 340 255 179 175 144 108 74 584 486 360 272 242 191 141 101 584 486 360 272 246 202 147 104 744 631 483 333 295 230 178 129 790 685 520 350 330 250 190 135 1012 831 667 437 425 345 261 177 1164 893 745 466 511 403 306 195 1651 1372 984 650 582 469 354 226 N/A 1930 1512 1112 707

LP FUEL CONSUMPTION (STANDBY)

MODEL SPECIFICATIONS NG Standby Rating @ 480V (kW/kVA) LP Standby Rating @ 480V (kW/kVA) NG Prime Rating @ 480V (kW/kVA) Motor Starting @ 35% V Dip (kVA) Sound Level Full Load dBA @ 23 feet Auto-Changeover Dual Fuel Full Load (cf/h) 75% Load (cf/h) 50% Load (cf/h) 25% Load (cf/h) Full Load (cf/h) 75% Load (cf/h) 50% Load (cf/h) 25% Load (cf/h)

180REZX 180/225 130/163 164/205 790 71

200REZX 200/250 130/163 175/219 990 71

250REZX 260/325 170/213 235/294

300REZX 300/375 210/263 270/338 1350

350REZX 355/444 240/300 300/375 1550 70

400REZX 400/500 260/325 360/450

70

70

71

NG FUEL CONSUMPTION (STANDBY) 1928 1501 1067 636 703 600 406 254 1776 1388 992 579 2115 1649 1158 706 703 600 406 254 1893 1473 1049 622 2782 2168 1521 928 926 789 532 335 2536 1974 1402 876 3462 2665 1875 1152 1196 861 640 427 3161 2435 1736 1091 3984 3053 2109 1253 1289 979 701 446 3635 2784 1949 1182 4231 3298 2317 1413 1409 1201 809 512 3856 3005 2137 1331

LP FUEL CONSUMPTION (STANDBY)

NG FUEL CONSUMPTION (PRIME) Full Load (cf/h) 75% Load (cf/h) 50% Load (cf/h) 25% Load (cf/h)

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

Call toll-free in the U.S. and Canada Kohler Power Kohler, 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.