Werner Schlenker-Deutz Power Systems

Training Center Mannheim
Basis und periphery of Deutz- Power-

Systems-Gasengines
Werner Schlenker
MM-O UP 18.09.2006 1
Pipe installation plan
MM-O UP 18.09.2006 2
Pioneers of Engine Technology
1864 1871 1872 1876
N. A. Otto and E. Langen start the Carl Benz and Gottlieb Daimler, technical The worlds first four stroke
worlds first engine company August Ritter director Wilhelm Maybach, head engine
start the of engine design
Mechanische
Werksttte in
Mannheim
1898 1907 1936

The first DEUTZ Ettore Bugatti, Take-over of
diesel engine director of Fahrzeugfabrik C.D.
automobil production Magirus AG in Ulm
1985 2001 2002 2005

Take-over of 125 years four The new 20-cylinder gas Start of DEUTZ Power
Motoren-Werke stroke engines engine with best-in-class Systems GmbH & Co. KG
Mannheim AG from Kln-Deutz efficiency of 44%
* DaimlerChrysler Classic, Konzernarchiv
MM-O UP 18.09.2006 3
Comprehensive range of engines between 180 and 4.000 kW
TCG 2015 180 - 240 kW
TCG 2016 K 323 - 700 kW
TCG 2016 555 - 800 kW
TCG 2020 K 970 - 1.400 kW
TCG 2020 1.050 - 2.000 kW
TCG 2032 3.000 - 4.000 kW
TCD 2016 551 - 775 kW*
TCD 2020 1.097 - 1.973 kW*
* for COP, 50 Hz
MM-O UP 18.09.2006 4
TCG 2016 K
Motortype V8 V 12 V 16
Boring / Stroke mm 132/160 132/160 132/160
Diplacement dm3 17,5 26,3 35,0
Gas naturalgas, sewagegas,landfillgas
MM-O UP 18.09.2006 5
TCG 2016 K: Data, 50 Hz, naturalgas
Scope
Frequency 50 Hz
Limit NOX <= 500 mg /mn3
Gas naturalgas
Methanenumber, min MZ 70
Exhaustpipes watercooled
Power kW 350 525 700
Speed min-1 1500 1500 1500
Boring / Stroke mm 132/160 132/160 132/160
Displacement dm3 17,5 26,3 35,0
MM-O UP 18.09.2006 6
TCG 2016 K: Data, 50 Hz, sewage - and landfillgas
Scope
Frequency 50 Hz
Limits NOX <= 500 mg / mn3
Sewagegas 65 % CH4, 35 % CO2
Landfillgas 50 % CH4, 27 % CO2, Rest N2
Heating value, min HU 5,0 kWh / mn3
Power kW 350 525 700
Speed min-1 1500 1500 1500
Boring / Stroke mm 132/160 132/160 132/160
MM-O UP 18.09.2006 7
Scope
Frequency 60 Hz
Limits NOX <= 500 mg /mn3 / 1,2 g/bhph
Gas naturalgas
Power kW / bhp 350 / 469 525 / 704 700 / 939
Speed min-1 1800 1800 1800
Boring / Stroke mm 132/160 132/160 132/160
MM-O UP 18.09.2006 8
Scope
Frequency 60 Hz
Limits NOX <= 500 mg / mn3/ 1,2 g/bhph
Power kW / bhp 350 / 469 525 / 704 700 / 939
Speed min-1 1800 1800 1800
Boring / Stroke mm 132/160 132/160 132/160
MM-O UP 18.09.2006 9
TCG 2016 K: Electric parts A-Side
MM-O UP 18.09.2006 10
TCG 2016 K: Eletrical parts B-Side
MM-O UP 18.09.2006 11
TCG 2016
Motortype V 12 V 16
Boring / Stroke mm 132/160 132/160
Diplacement dm3 26,3 35,0
MM-O UP 18.09.2006 12
TCG 2016: Data, 50 Hz, naturalgas
Scope
Frequency 50 Hz
Limits NOX <= 500 mg /mn3
Gas naturalgas
Exhaustpipes trocken
Motortype V 12 V 16
Power kW 600 800
Speed min-1 1500 1500
MM-O UP 18.09.2006 13
TCG 2016: Daten, 50 Hz, sewage - and landfillgas
Scope
Frequency 50 Hz
Motortype V 12 V 16
Power kW 555 740
Speed min-1 1500 1500

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TCG 2016: Electric parts A-Side
MM-O UP 18.09.2006 15
TCG 2016: Eletrical parts B-Side
MM-O UP 18.09.2006 16
TCG 2020 K
Motortyp V 12 V 16
MM-O UP 18.09.2006 17
Scope
Frequency 50 Hz
Gasart Erdgas
Motortype V 12 V 16
Power kW 1050 1400
Speed min-1 1500 1500
MM-O UP 18.09.2006 18
Scope
Frequency 50 Hz
Exhaustpipes wassergekhlt
Motortype V 12 V 16
Power kW 970 1294
Speed min-1 1500 1500
MM-O UP 18.09.2006 19
Scope
Frequency 60 Hz
Gas naturalgas
Motortype V 12 V 16
Power kW / bhp 1050 / 1408 1400 / 1877
Speed min-1 1800 1800
MM-O UP 18.09.2006 20
Scope
Frequency 50 Hz
Motortype V 12 V 16
Power kW / bhp 1050 / 1408 1400 / 1877
Speed min-1 1800 1800
MM-O UP 18.09.2006 21
TCG 2020 K: Electric parts A-Side
90008-0
MM-O UP 18.09.2006 22
TCG 2020 K: Eletrical parts B-Side
90009-0
MM-O UP 18.09.2006 23
TCG 2020
Motortyp V 12 V 16 V 20
Boring / Stroke mm 170/195 170/195 170/195
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Scope
Frequenz 50 Hz
Gas naturalgas
Exhaustpipes dry
Motortype V 12 V 16 V 20
Power kW 1200 1600 2000
Speed min-1 1500 1500 1500
Boring / Stroke mm 170/195 170/195 170/195
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TCG 2020: Daten, 50 Hz, sewage - and landfillgas
Rahmenbedingungen
Frequency 50 Hz
Exhaustpipes dry
Motortyp V 12 V 16
Power kW 1050 1400 1750
Speed min-1 1500 1500 1500
Boring / Stroke mm 170/195 170/195 170/195
MM-O UP 18.09.2006 26
90008-0
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90009-0
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TCG 2032
Motortype V 12 V 16
Gas naturalgas
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Scope
Frequency 50 Hz
Gas naturalgas
Motortyp V 12 V 16
Power kW 3000 4000
Speed min-1 1000 1000
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Scope
Frequency 60 Hz
Gas naturalgas
Motortype V 12 V 16
Power kW / bhp 2700 / 3621 3600 / 4828
Speed min-1 900 900
MM-O UP 18.09.2006 31
MM-O UP 18.09.2006 32
1 Widerstandsthermometer Khlwassertemperatur Motoraustritt (206)

2 Widerstandsthermometer Khlwassertemperatur Motoreintritt (207)
3 Thermoelement Receivertemperatur (201)
4 Klopfsensor (241 ... 248)
5 Druckaufnehmer Schmierldruck (302)
6 Multifunktionsschiene Zylinderreihe A
7 Index-Aufnehmer Zndung (319)
8 Thermoelement Brennraumtemperatur (461 ... 468)
9 Elektrisches Vorwrmeaggregat (156)
10 Schrittmotor (1.5.16)
11 Widerstandsthermometer Ansauglufttemperatur (203)
12 Nherungsschalter Multi-Gas-Mischer (159)
13 Schwimmerschalter Schmierlniveau (234)
14 Druckaufnehmer Schmierldruck (196)
15 Widerstandsthermometer Khlwassertemperatur vor Gemischkhler (202)
16 Nherungsschalter Multi-Gas-Mischer (357)
17 Widerstandsthermometer Schmierltemperatur (208)
18 Stellgert (197)
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MM-O UP 18.09.2006 34
1 Klopfsensor (251258)
2 Thermoelement Brennraumtemperatur (471478)
3 Thermoelement Receivertemperatur (378)
4 Schrittmotor (1.5.20)
5 Widerstandsthermometer Ansauglufttemperatur (377)
6 Multifunktionsschiene Zylinderreihe B
7 Elektro-Vorschmierpumpe
8 Anlassverblockung bei Trnmaschinenbetrieb(TVR)
9 Druckluft-Anlasser (VK1)
10 Druckaufnehmer Anlassdruck (371)
11 Drehzahlaufnehmer (200)
12 Druckaufnehmer Kurbelgehuse-berdruck(145)
13 Zndungssystem TEM-ZS1/ZS3
MM-O UP 18.09.2006 35
TEM Total Electronic Management
f Control and supervision of generating set

f Control and supervision of generating set
auxiliaries
f Minimal exhaust emission (below
international limits)
f Easy and user friendly operation
f Optimal performance under all operating
ranges
AR Exhaust Stack HWP Hot Water Pump

ASD Silencer K Clutch
ATL Turbo Charger KWP Cool Water Pump
AWT Exhaust Heat Exchanger tH Hot Water Feed Temp.
G Generator tM Inlet Temp. Engine
KWT Cooling Water Heat Exchanger
MM-O UP 18.09.2006 36
Advantages of Turbocharging
f Optimal efficiency
f Homogenous gas-air mixture in
turbocharger and mixture cooler
f No gas pre-compression required
f Nox, CO ad HC limits are reliably
kept
ATL Exhaust turbocharger GR Gas control unit

D Throttle GK Mixture cooler
F Air filter M Motor actuator
G Generator MM Gas engine
GM Gas-air mixer tB Combustion chamber temp.
MM-O UP 18.09.2006 37
Development
f Two cylinders have one exhaust module

(PEARL)
f Exhaust pipe is high temperature
Inlet manifold resistant
f Axial movement is minimized (flex.
compensators)
f 4-belt flange between module and
cylinder head
f Turbocharger with high--efficency
f Improved crankcase breather system
flow
Exhaust f Reduced mixture charge losses
f Higher exhaust energy
f Higher mech. output with constant
thermal stress of parts
PEARL-module compensator f Optimised combustion
MM-O UP 18.09.2006 38
Engine Type Designation
New T C G 2032 V _
K
Exhaust Gas Turbocharging T
Mixture Charging Cooling C
Gas Engine G
Model 2032
V- Engine V
Number of Cylinder 12, 16
Previously T B G 632 V _
K
Exhaust Gas Turbocharging T
Mixture Charging Cooling B
Gas Engine G
Model 620
V- Engine V
Number of Cylinder 12, 16
MM-O UP 18.09.2006 39
suction cycle compression cycle
working cycle exhaust cycle
MM-O UP 18.09.2006 40
Four Stroke Principle Outlet closes TDC
Inlet opens
Suction
Compression
Working
Ejection
Inlet closes
Outlet opens
BDC
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Homogeneous combustion
MM-O UP 18.09.2006 42
Rating plate 1 Engine type designation
2 Year
3 Engine number
4, 5, 6 Performance abbreviation according to DIN ISO
3046 Part 7 and abbreviation for the gas type 1)
25 air temperature, 30% air humidity; 1 bar pressure
7, 8, 9 Numeric value of the performance in kW
10, 11, 12 Engine speed in rpm
13, 14. An * or ** in front of the performance abbreviation
refers to the corresponding NOx emission, see NOX emission in mg
15 Height above sea level (conditions at installation site)
16 Air pressure px in mbar (conditions at installation site)
17 Charge air coolant temperature tcx in C
(conditions at installation site)
18 Relative humidity x in %
19 Mixture coolant temperature tcx in C
20 Numeric value of performance of the oil pump in kW (F)
Abbreviation for the gas type

n Natural gas
b Biogas
s Sewage gas
l Landfill gas
m Pit gas
p Propane gas
MM-O UP 18.09.2006 43
Chemical Designations
CH4 Methan CO2 Carbon dioxide
CO Carbon monoxide H2 Hydrogen
S Sulphur N Nitrogen
NO Nitrogen oxide NO2 Nitrogen dioxide
HC Hydrocarbon O2 Oxygen
Nox Nitrogen oxides ( mixture of NO + NO2 )
Problematic substances:
Calciumsulfat CaSO44
Ammoniak NH33
Schwefelwasserstoff H22S
Siloxane SiOXX
MM-O UP 18.09.2006 44
Results on Gas air mixer
MM-O UP 18.09.2006 45
Results on intercooler
MM-O UP 18.09.2006 46
Results on piston and cylinderliner
MM-O UP 18.09.2006 47
Auswirkungen Zylinderkpfe
MM-O UP 18.09.2006 48
Methan Number
The methane number (MN) provides information on the knock resistance of the gas.
The higher the methane number, the greater the knock resistance of the gas.
Methane MN 100
Landfill gas MN ca. 140
Sewage gas MN ca. 135
Natural gas MN 75 92 ( Russian gas )
Natural gas MN 65 80 ( North Sea gas )
Propane MN 35
Butane MN 10
Hydrogen MN 0
MM-O UP 18.09.2006 49
Methane Content
Methane content = CH4 in %
Natural gas
Methane content ~ 81% CH4
Landfill gas
Methane content > 50% CH4 100% power

Methane content > 38% CH4 power reduction
Methane content < 38% CH4 engine shutdown
Sewage gas
30% CO2 = 70% CH4
MM-O UP 18.09.2006 50
Gas composition
Natural gas Sewage gas
C nH m CO 2 C nHm
N2 CO 2
5% 1% 13% 0,3%
33%
CH 4 CH 4 H2S
81% 66% 0,7%
Coke gas
CO CO2 CH4
N2 5% 3% 22%
14%
CnHm
3%
H2
53%
MM-O UP 18.09.2006 51
Lambda
Owing to the requisite closeness of the mixture setting to the stoichiometric air ratio, the process has
been given the designation lambda 1 process.
lambda numbers the air volume provided for the combustion:
lambda 1 = 1 part gas and approx. 10 parts air
G lambda 1 with 3-way catalyst
TBG lambda 1.4 ( lean mixture charging TA, air )
TBG lambda 1.6 ( lean mixture charging TA, air )
MM-O UP 18.09.2006 52
efficiency
exhaust emission
3 way catalist
lean burn
air ratio
MM-O UP 18.09.2006 53
TA Air = Technical Instructions, Air
Limit values for auto-ignition engine systems
Dust (soot) 20 mg/m3
Formaldehyde 60 mg/m3
Hydrocarbons No limit values
CO Spark ignition engines with biogas and sewage < 3MWth 1000 mg/m3
gas
> 3MWth 650 mg/m3
Landfill gas 650 mg/m3
Other gases and liquid fuels 650 mg/m3
Nitrogen oxides NOx Lean gas engines, all gases 500 mg/m3
Other 4-stroke Otto engines 250 mg/m3
Landfill gas engines 500 mg/m3
Engines for emergency operation or mileage < 300 h / year

Dust (soot) 20 mg/m3
Nitrogen oxides NOx No limit values
MM-O UP 18.09.2006 54
Knocking
fDefinition: Knocking results out of a spontaneus combustion in the single cylinders
(uncontrollable combustion)
f Cause: Methanenumber (gas changing)

Ignition point ( advanced ignition)
Air-fuel mixture (rich)
Scaling
High temperature of air-fuel mixture,high temprature at different engine
components so called( Hot Spots)for example ;valves.
fNegative effects: Through the spontaneus combustion spots we have lots of explosive combustions
which raisses high temperature(piston volume extansion) and high pressure, also the hits of the single
combustions will bring the pistons in vibrations, the temperature disrupt the oilfilm between pistonrings and
cylinderliner and con rod crankshaft(hammering) and will smelt the pistons and valves.
MM-O UP 18.09.2006 55
The engine microphone
The engine microphone
MM-O UP 18.09.2006 56
Details of a Knockingsensor
seismic mass
casing body
electrikal
connection
piezo electrik ceramik

carrier
MM-O UP 18.09.2006 57
Solution
The elemination of knocking has to be very fast .1500U/min we have 750 ignitions per minute
or 12.5 per sec. 1 combustion cycle = 80 ms
-To take influence of gas-mixture is not possible
-To change or react of a temperature is to slow
-When we detect knocking we have to react immediatly.Take pressure and temperature out of
the cylinder. We can realize this if we change the ignition point from advanced to late so we
dislocate the combustion in to the exhaust and we downscale the pressure and temperature in
the cylinder.
MM-O UP 18.09.2006 58
Ignition
Operation an engine with a wrong ignition point can have the following effects:
- The engine starts knocking
- comply with the exhaust emission is not possible
- The degree of efficiency change for the worse
- Through lower exhaustgas- temperatures there is not enough energy for the
turbo-charger so we have insufficient air-charge-pressure to get 100% power.
MM-O UP 18.09.2006 59
Ignition point adv. + late
f Ignition point : stated in degree crankshaftankle(KW) 12 oclock

(TDC)
f before TDC. Ignition before top dead center , to be LATE
near with main combustion capacity and main pressure
at the end of the compression stroke (biggest Force) . 1 oclock
2 oclock
Advanced
f
Explanation : Date with a girl
1 oclock both arrive at the same time

everybody is happy.
2 o`clock the girl is to early, alone and pissed Direction of rotation
crankshaft
off! Realy pissed off!!!
12 oclock girl is to late but which girl is punctualy!
Men are used to wait. ALAS!
MM-O UP 18.09.2006 60
Advanced ignition point
Operating with an advanced ignition point brings the ignition pressure to rise and the danger
of knocking is given.
This status is shown by the temperatures :

Resulting from an advanced ignition there are shorter combustion-phaseals but longer
expansion-phaseals. Temperature falls after engine, but after cat. temperature rises trough
higher contigent of unburnt air-fuel-mixture!
Through combustion-chamber-contoller the air-fuel-mixture gets lean until misfire limit .

Cause of unburnt air-gas-mixture in the exhaust , the catalyzer is jeopardized and can
be destroyd be the high levelled temperatures.
Ignition point late
If the ignition point is to late there is a downscale of the ignition pressure
and a dislocated combustion. Higher temperature at engine components
Which means higher abrasion!
In the worst case the electrodes of the spark plugs start to smelt and even
piston jamming is possible.
Combustion-chamber-controller changes air-fuel-mixture to
rich and temperature after engine is high levelled.
Geregelte Verbrennung
ZZP zu spt
Ignition point late

Uncontrolled Combustion, Pressure Curve
Motored engine
MM-O UP 18.09.2006 63
Normal ignition PZ-MAX 80.69 BAR
MM-O UP 18.09.2006 64

Advanced ignition PZ-MAX 131.49 BAR
MM-O UP 18.09.2006 65

Knocking PZ-MAX 136.94 BAR
MM-O UP 18.09.2006 66

Knocking PZ-MAX 136.94 BAR
Adv. ignition + knocking PZ-MAX 153.27 BAR
MM-O UP 18.09.2006 67
Pressure Curve
nominal ignition
pressure ca. 90 BAR
Advanced ignition
pressure ca. 160 BAR
Knocking
Pressure ca. 165 BAR
Adv. ignition + Knocking
Pressure ca. 200 BAR
MM-O UP 18.09.2006 68
Uncontrolled Combustion, Temperature Curve
Motored engine
MM-O UP 18.09.2006 69
Normal ignition 1475C
MM-O UP 18.09.2006 70

Advanced ignition 1955C
MM-O UP 18.09.2006 71

Knocking 2300C
MM-O UP 18.09.2006 72

Premature ignition 1955C
Knocking 2300C
Premature ignition + knocking 2500C
MM-O UP 18.09.2006 73
Temperature Curve
Nominal ignition 1475C

Knocking 2300C
Adv. ignition + Knocking 2500C
MM-O UP 18.09.2006 74
Anti-knocking Regulation Parameters (AKR)
Vorher mit Folie erklren!
MM-O UP 18.09.2006 75
Anti-knocking Regulation Screen (AKR Screen)
MM-O UP 18.09.2006 76
Previous Knock History
MM-O UP 18.09.2006 77
Alarm notice Knocking
Critical fault check engine
After this alarm its absolutely necessary to control the bearings, cause the frequency of
knocking and of a busted bearing are similar.Its important to open the hatch cover and
check the bearings of fretting corrosion also submit the engine to a careful examination with
an endoscope.
At TCG 2016 the control of the bearing is only possible when the oil pan is relieved!
Only after a careful examination the alarm can be resetet and a start of the engine is allowed.
MM-O UP 18.09.2006 78
Damage
MM-O UP 18.09.2006 79
Ignition systems
Pre chamber Open combustion chaamber
MM-O UP 18.09.2006 80
Convential spark plug
Adjustment: 0,25 mm spark gap
MM-O UP 18.09.2006 81
Pre chamber spark plug
MM-O UP 18.09.2006 82
Pre-chamber Spark Plug
Demonstration Iso-surface 1000 C
t = 0,30 ms t = 0,50 ms t = 0,65 ms t = 0,70 ms t = 0,75 ms
MM-O UP 18.09.2006 83
Features of the pre chamber spark plug
f Reduced ignition voltage

f Higher life time with out cheking spark gap
f No deformation of spark plug while assemble
f Increase of ignition energy done by rays of flame
f Less combustion pressure staggering with smaller dynamic engine
burden
f Increase of efficiency up to 1-2% ( efficient combustion cause of the
swirl bores)
f Better engineperformance through reduced abrasion, less idle time
and lower running - and maintenance expenses
MM-O UP 18.09.2006 84
Deposits
Clean bores but be

aware of tangential
direction of the bore
MM-O UP 18.09.2006 85
Short circuit bridges
Removing of the short circuit bridges:

- Knock spark plug on a hard surface but be
aware of the thread.
- Clean pre chamber with compressed air
MM-O UP 18.09.2006 86
Maintenance of pre chamber spark plug
f Before reinstallation of the spark plug always use a new seal ring
Attention: it must be provided that the seal ring is installed in the right
direction
f Visual control of
f thread
f bores
f Spark plug lead and spark plug connector
f condition of spark plug
MM-O UP 18.09.2006 87
Spark plug diagnostics
MM-O UP 18.09.2006 88
Gas Control Line RMG, with Donkin
Inletpressure:
1 Flange 6 Solenoid valve TR 0199-99-3017/ 3

2 Shut-off device (ballcock) Flame flashover protection
21.03.2008
3 Pressure gauge with pushbutton tap Reducer
4 Gas filter Gas pressure regulator 20 - 200 mbar magnetic valves
5 Gas pressure gauge Outlet pipe 20 500 mbar pneumatic valves

Flange
MM-O UP 18.09.2006 89
Gas Control Line RMG, with RMG 320
1 Ball valve 6 Solenoid valve

2 Gas filter 7 Gas pressure regulator RMG
320
3 Manometer
8 Pressure gauge
4 Pressure monitor
9 Gas pressure
5 Solenoid valve
10 Air pressure
MM-O UP 18.09.2006 90
Gas Pressure Regulator RMG 320
MM-O UP 18.09.2006 91
Gas Pressure Regulator Donkin
MM-O UP 18.09.2006 92
Sensors
MM-O UP 18.09.2006 93
Characteristic of the PT100
Temperatur / C PT100 / Ohm PT1000 / Ohm
50 80,83 808,3
45 82,29 822,9
40 84,27 842,7
35 86,25 862,5
30 88,22 882,2
25 90,19 901,9
20 92,16 921,6
15 94,12 941,2
10 96,09 960,9
5 98,04 980,4
0 100 1000
5 101,95 1019,5
10 103,9 1039
15 105,85 1058,5
20 107,79 1077,9
25 109,73 1097,3
30 111,67 1116,7
35 113,61 1136,1
40 115,54 1155,4
45 117,47 1174,7
50 119,4 1194
55 121,32 1213,2
60 123,24 1232,4
65 125,16 1251,6
70 127,07 1270,7
75 128,98 1289,8
80 130,89 1308,9
85 132,8 1328
90 134,7 1347
95 136,6 1366
100 138,5 1385
105 140,39 1403,9
110 142,29 1422,9
150 157,31 1573,1
200 175,84 1758,4
MM-O UP 18.09.2006 94
Thermo - Couple
Type Material Temperature- Accuracy of Colour of Lines Thermo electrical

(+) - Line / (-) - Line range Measurement (+) - Line (-) - Line Potential at
100 C (212 F)
Brown White
Black White
Red White
Green White
Red White
Yellow White
Yellow White
MM-O UP 18.09.2006 95
Default startsteps gas- air mixer
Steps naturalgas
Steps sewagegas
Steps landfillgas
MM-O UP 18.09.2006 96
Gas Mixture Formation
The mixture of gas and air into a combustible mixture occurs immediately before the turbocharger, in the
so-called mixer.
The mixer is a Venturi pipe, i.e. a pipe contraction favouring flow with a gradual expansion out again.
As a result of the design, the flow only experiences minimum pressure losses and hence only minimum
filling losses in the cylinders.
The flow has the highest speed at the narrowest point.
Here the gas is admixed to the core flow radially from outside via an annular gap through the resulting
vacuum.
This type of admixture has the advantage that the quantitative ratio of gas to air almost always remains
constant even with significant changes in the mixture sucked through, and only slightly departs for a brief
period from the so-called lambda window in which the safe and economical operation range of the
engine lies.
A gas cleaning option in the gas path remains connected in series for setting the air ratio and for small
corrections, the adjustable gas gap.
The gas mixing volume is controlled via the throttle valve or rotary disk valve.
MM-O UP 18.09.2006 97
Gas air mixer
Hands of the gas

regulator !
1 Gas Inlet
2 Air Inlet
3 Gas-Air Mixture Outlet
4 Connection linkage to the stepper motor
5 Gas gap
MM-O UP 18.09.2006 98
Gas-Air Mixer
f No pressure loss during mixture

formation. Enhanced power
output at max. efficiency. Gas
Motor-
f Also with changing mass flow of actuatort
the gas, the gas air ratio
remains constant. Air
Gas-air-
f Using the combustion mixture
temperature, e.g. the emission
control of the engine is
governed through TEM by
adjusting the gas air ratio.
MM-O UP 18.09.2006 99
Throttle valve and rotary flap
TCG 2016 K
TCG 2016
TCG 2020 K V12 , V16
TCG 2020 V12 , V16
TCG 2020 V20
TCG 2032
MM-O UP 18.09.2006 100

Exhaust Turbocharger
Compressor Side Exhaust Side
MM-O UP 18.09.2006 101

Exhaust Turbocharger
1 Lube oil inlet

2 Bearing housing
3 Shaft
4 Exhaust gas inlet
5 Turbine wheel
6 Exhaust gas outlet
7 Exhaust gas inlet
housing
8 Radial slide bearing
9 Radial slide bearing
10 Lube oil outlet
11 Mixture outlet
12 Compressor housing
13 Compressor wheel
14 Mixture inlet
MM-O UP 18.09.2006 102

Installing the Speed Measuring Sensor (optional)
Bearing Housing
Speed Sensor
Flange Plug
Assembly Option
Cable Connector
Sealing Disk
Voltage Limiting Module
Gasket
Lock Screw
Line Amplifier (optional)
Connecting Cable
MM-O UP 18.09.2006 103
ATL power regarding altitude and intake temperature
110
40 C 35 C 27 C
100
90
power [%]
80
70
60
0 200 400 600 800
height [m]
MM-O UP 18.09.2006 104
Testbed Report
MM-O UP 18.09.2006 105

Schematic Diagram / Charging
1 Intake Air
2 Air filter
3 Filtered Air
4 Gas / Air mixer
5 Gas
6 Mixture to compressor
7 Compressor
8 From compressor
9 Mixture cooler
10 Cooled mixture
11 Inlet valve
12 Outlet valve
13 To exhaust gas turbine
14 Exhaust gas turbine
15 To silencer
MM-O UP 18.09.2006 106

Installation and Setting Specifications, Flywheel
Note:
Only slightly magnetic sensors (pickups) may be used.
Procedure:
- Screw in sensor until it rests on the toothed ring of the flywheel.
- Screw out by the spacing according to the table
- Continue to unscrew until the alignment corresponding to the table is attained. Marking
Sensor Series
Jaquet 616 / 2016 620 / 2020 632 / 2032
Type DSD 1805.50 AV DSD 1805.50 AV DSD 1805.50 AV
Drawing No. 1229 9989 1229 9988 1229 9988
Length 105 mm 52 mm 52 mm
Spacing 1 revolution
Alignment Marking in direction of flywheel rotation
MM-O UP 18.09.2006 107

Camshaft pick-up (Index Pick-Up)
Brown
Yellow
Blue
Note
- Only slightly magnetic sensors (pickups) may be used
Procedure:
- Screw in sensor until it rests on the pin of the camshaftwheel.
- Screw out by the spacing according to the table
MM-O UP 18.09.2006 108

Adjustment of the camshaft Pick-Ups
Pick up Engine types

Jaquet, old 616 / 2016 620 / 2020 632 / 2032
Abstand 2 Rotation 2 Rotation 3 Rotation
Ausrichtung 12 Uhr 11 Uhr 6 Uhr

Altronic 616 / 2016 620 / 2020 632 / 2032
Abstand 1 1 Rotation 1 1 Rotation 1 1 Rotation
Jaquet, new 616 / 2016 620 / 2020 632 / 2032

Abstand 1 1 Rotation 1 1 Rotation 1 1 Rotation
MM-O UP 18.09.2006 109

Calculation of the new camshaft offset
example 1:
Values test report or TEM: ignition point = 25; camshaft offset = 102.5
scannend ZZP (Ignition point) (after assembling) = 20
Correction value = corrected Reset Pos. = =
example 2:
Values like above, scannend ZZP (Ignition point) ( after assembling)= 27
Correction value = corrected Reset Pos. = =
Enter the corrected Reset Pos.in TEM. Then starting engine and scan ignition point again.
MM-O UP 18.09.2006 110

Lube Oil Level Sensor
1 Vent Line
2 Electrical Connection
3 Gage-Glass
4 Connecting Line to the Oil Pan
MM-O UP 18.09.2006 111

Design
1 Safety switching point (NC)

Overfill engine stop
2 Operating switching point
Max. lube oil level,
Solenoid valve closes lube oil supply is interrupted
3 Operating switching point
1 Min. lube oil level,
Solenoid valve opens lube oil is refilled
4 Safety switching point (NC)

Oil shortage engine stop,
2 The indication Oil Min. appears in the TEM display
3 The engine can only be started after a pre-lubrication
of at least 20 minutes after this indication.
MM-O UP 18.09.2006 112

Lube Oil Level Sensor
Reed - Contact
MM-O UP 18.09.2006 113

Checking the Lube Oil Level Sensor
Oillevel MAX
Filling ON / OFF
Oillevel MIN
Oillevel Sensor value
Max
470
750
180
Filling OFF 680

Filling On 280
Min 110
MM-O UP 18.09.2006 114
Pipe installation plan
MM-O UP 18.09.2006 115

Exhaust system
Abgasgegendruck > 50 mbar Warnung Motor luft

weiter
MM-O UP 18.09.2006 118

Engine cooling
MM-O UP 18.09.2006 119

Werner Schlenker-Deutz Power Systems

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Training Center Mannheim

Basis und periphery of Deutz- Power-

1898 1907 1936

1985 2001 2002 2005

TCG 2015 180 - 240 kW

TCG 2016 K 323 - 700 kW

TCG 2016 555 - 800 kW

TCG 2020 K 970 - 1.400 kW

TCG 2020 1.050 - 2.000 kW

TCG 2032 3.000 - 4.000 kW

TCD 2016 551 - 775 kW*

TCD 2020 1.097 - 1.973 kW*

Limit NOX <= 500 mg /mn3

Limits NOX <= 500 mg / mn3

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Limits NOX <= 500 mg /mn3 / 1,2 g/bhph

Limits NOX <= 500 mg / mn3/ 1,2 g/bhph

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Limits NOX <= 500 mg /mn3

Limits NOX <= 500 mg / mn3

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Boring / Stroke mm 132/160 132/160

Limits NOX <= 500 mg /mn3

Limits NOX <= 500 mg / mn3

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Limits NOX <= 500 mg / mn3/ 1,2 g/bhph

Limits NOX <= 500 mg / mn3/ 1,2 g/bhph

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Limits NOX <= 500 mg /mn3

Limits NOX <= 500 mg / mn3

Sewagegas 65 % CH4, 35 % CO2

Landfillgas 50 % CH4, 27 % CO2, Rest N2

Heating value, min HU 5,0 kWh / mn3

Limits NOX <= 500 mg /mn3

Power kW 3000 4000

Speed min-1 1000 1000

Boring / Stroke mm 260/320 260/320

Diplacement dm3 203,9 271,8

Limits NOX <= 500 mg / mn3/ 1,2 g/bhph

Power kW / bhp 2700 / 3621 3600 / 4828

Speed min-1 900 900

Boring / Stroke mm 260/320 260/320

Diplacement dm3 203,9 271,8

1 Widerstandsthermometer Khlwassertemperatur Motoraustritt (206)

f Control and supervision of generating set

AR Exhaust Stack HWP Hot Water Pump

ATL Exhaust turbocharger GR Gas control unit

f Two cylinders have one exhaust module

working cycle exhaust cycle

Abbreviation for the gas type

CH4 Methan CO2 Carbon dioxide

CO Carbon monoxide H2 Hydrogen

NO Nitrogen oxide NO2 Nitrogen dioxide

Nox Nitrogen oxides ( mixture of NO + NO2 )