Installation Guideline Gas ENU

Application Guidebook
Application and installation guidelines

for high-speed MTU Onsite Energy gas engine-generator sets
E
© 2015 Copyright MTU Friedrichshafen GmbH
This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of MTU Friedrichshafen GmbH. This particularly applies to its reproduction, distribution, editing, translation, micro-
filming and storage or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. MTU Friedrichshafen GmbH
reserves the right to change, delete or supplement the information provided as and when required.
Table of Contents
1 General Information 3.3.1 Engine-generator set – Overview 71
3.3.2 One-line diagram 75
1.1 About this manual 5 3.3.3 Dimensioning – Gas genset 76
1.2 Company presentation MTU Onsite Engergy 7 3.3.4 P&I diagram 79
1.3 Product portfolio 10
3.4 Engine-generator set - components 80
1.4 MTU Onsite Energy system business 13 3.4.1 Engines 80
1.5 Test conditions for engines and gensets 15 3.4.2 Generator 81
1.6 Configuration planning 16 3.4.2.1 Generator 81
1.7 CE conformity 17 3.4.2.2 Excitation systems 84
3.4.2.3 Degrees of protection 85
2 Basic Knowledge 3.4.3 Fuel System 87
3.4.3.1 Fuel system – Description 87
2.1 Use of gensets 18 3.4.3.2 Gas train 88
2.2 Comparison between diesel genset and gas 3.4.3.3 Gas mixer 89
genset 20 3.4.3.4 Installation of the gas system 90
2.3 IPAS application engineering tool 21 3.4.4 Intake Air System 91
3.4.4.1 Intake air system – Description 91
2.4 Rating program HP-Spec (Power System
3.4.4.2 Air filter 92
Sizing and Specification Program) 22
3.4.4.3 Differential pressure 93
3.4.5 Exhaust System 94
3 Application engineering for gas gensets 3.4.5.1 Exhaust system – Description 94
3.4.6 Lube Oil System 95
3.1 Basic Knowledge 23 3.4.6.1 Lube oil system 95
3.1.1 Referenced documents and standards 23
3.4.7 Cooling System 97
3.1.2 General conditions 25
3.4.7.1 Cooling system – Description 97
3.1.3 Power properties – Electrical power 28
3.4.7.2 Preheater 99
3.1.4 Key planning parameters – Electrical power 32
3.4.7.3 Engine coolant heat exchanger 100
3.1.5 Power properties – Thermal power 33
3.4.7.4 Fan cooler 101
3.1.6 Application groups – Gas genset 34
3.4.8 Starting Equipment 102
3.1.7 Basic Operations 37
3.4.8.1 Starter system 102
3.1.7.1 Mains operation 37
3.4.8.2 Batteries 103
3.1.7.2 Cogeneration – Gas genset 39
3.4.8.3 Battery charger 104
3.1.7.3 Trigeneration – Gas genset 43
3.4.9 Power Electronics 105
3.1.7.4 Gas operation – Gas genset 44
3.4.9.1 Controllers 105
3.1.7.5 Operational limits for gas gensets 47
3.4.9.2 Control versions – Gas genset 108
3.2 Customer Requirements 48 3.5 Infrastructure 111
3.2.1 Emissions 48
3.5.1 Assembly instructions 111
3.2.2 Requirements Related to Electric Load 50
3.5.2 Engine-Generator Set Room 112
3.2.2.1 Load properties and special features 50
3.5.2.1 General requirements 112
3.2.2.2 Current load types 55
3.5.2.2 Requirements for premises 113
3.2.2.3 Load management 56
3.5.2.3 Installation compartment – Requirements 114
3.2.2.4 Power calculation 57
3.5.2.4 Requirements of switchgear room 117
3.2.3 Requirements Related to Thermal Load 59
3.5.2.5 Installation recommendations 118
3.2.3.1 Load properties and special features 59
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3.5.3 Fuel supply system – Gas genset 119

3.2.3.2 Power calculation 62
3.5.4 Ventilation system 120
3.2.4 Fuel Requirements 64
3.5.4.1 Ventilation 120
3.2.4.1 Gas – Requirements 64
3.5.4.2 Combustion air 122
3.2.5 Power Rating 65
3.5.4.3 Compartment air 123
3.2.5.1 Influencing factors on power 65
3.5.4.4 Air pipelines 125
3.2.5.2 Engine-generator set – Power 68
3.5.4.5 Safety requirements of the ventilation 126
3.2.5.3 Power ranges – Gas gensets from MTU
3.5.5 Exhaust System 127
Onsite Energy 69
3.5.5.1 Requirements of the exhaust system 127
3.3 Planning Criteria 71 3.5.5.2 Configuration of the exhaust system 128
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3.5.5.3 Exhaust pipe bellows 129 3.6.1 Transporting, lifting and storing 164
3.5.5.4 Exhaust pipe 133
3.5.5.5 Exhaust silencer 134
3.7 Validation and Commissioning 165
3.7.1 Validation and commissioning 165
3.5.5.6 Exhaust gas heat exchanger 135
3.5.5.7 Exhaust flue 136
3.5.6 Lube Oil Supply And Disposal System 137 4 Drawings
3.5.6.1 Oil line 137
3.5.6.2 Oil – Change 138 4.1 Gas genset - planning drawing 169
3.5.6.3 Oil replenishment device 139
3.5.7 Coolant Supply System 141
5 Diagrams
3.5.7.1 Configuration of the cooling system 141
3.5.7.2 Coolant pipework 142 5.1 One-line diagram - gas genset (MMC4000) 183
3.5.8 Cabling 144 5.2 One-line diagram - gas genset (MIP4000) 185
3.5.8.1 Cabling and grounding 144
5.3 One-line diagram - gas genset (KWK400) 187
3.5.8.2 Wiring – Standards and guidelines 145
3.5.8.3 Cable list 147
3.5.8.4 Line groups 149 6 Piping and Display Scheme
3.5.8.5 Generator cabling 152
6.1 R&I-scheme - gas genset with 12V4000L32
3.5.8.6 Cable routing 155
3.5.8.7 Battery connection 157
engine 191
3.5.8.8 Installation for intrinsically safe circuits 159
3.5.8.9 Electromagnetic compatibility – EMC 160 7 Appendix A
3.5.8.10 Equipotential bonding, protective conductor
and grounding 162 7.1 MTU contact persons/service partners 193
3.5.8.11 Cabling – Check and testing 163
8 Appendix B
3.6 Transport 164
8.1 Index 194
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1 General Information
1.1 About this manual
This application engineering manual describes the specification and application of systems for generating
electricity, heat and/or cold from MTU Onsite Energy. The main purpose of this manual is to support stand-
ard system business for high-speed gensets.
Structure of the manual

The project planning manual corresponds to the sequence of a project - starting with the request for quota-
tion, through consultation and on to project processing. The project planning manual consists of the general
section "Basic knowledge - general" and the specific section "Application engineering". The first section ex-
plains basic facts that are important when planning power and heat generation systems. The second section
is divided into the application engineering of gas gensets and application engineering of diesel gensets. Both
have the same structure in the following subsections:
• Basic knowledge
• Customer requirements (request for quotation)
• Planning criteria
• Engine-generator set - components
• Infrastructure
• Transportation
• Validation and commissioning
In the subsection Basic knowledge, the basic terms and components of a system for electricity, heat and/or
cooling energy generation are explained. The various operating modes are presented, and the general condi-
tions as well as operational limits and legal specifications are stipulated. A general explanation is provided as
to how a genset or a plant from MTU Onsite Energy is operated and which energy forms are made available.
A reference is already made here to aspects that are important for subsequent planning.
The subsection Customer requirements explains in detail the typical customer requirements of a system for
electricity, heat and/or cooling energy generation. Factors that influence the performance of the system are
presented.
In the case of a project, the recorded customer requirements are adopted in the planning of the genset or
plant. The selection options of the genset components and the infrastructure are listed in the following sub-
sections.
The function of the components available for selection is explained in the subsection Engine-generator set -
components. Here, the interconnections that have to be observed when planning complex plants are pre-
sented.
In the Infrastructure subsection, the assemblies and interfaces around the genset are explained. Each gen-
set, whether a stand alone or part of a plant, requires a certain infrastructure to function correctly.
Products from MTU Onsite Energy are configured as fixed installations or mobile gensets. For this reason, a
separate chapter has been dedicated to transport with information on special features and safety aspects.
The project is completed with validation and commissioning of the machine. This chapter not only lists the
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basis sequences and steps that have to be observed, but also refers to documents and checklists offered by
MTU Onsite Energy to guarantee a smooth process.
Target group
The project planning manual is intended for system integrators, MTU distributors, MTU service partners and
MTU project planners. It applies to all worldwide available high-speed MTU Onsite Energy systems for elec-
tricity, heat and cooling power generation.
An assumption is made that readers have basic knowledge of technology and physics.
E 2015-08 | General Information | 5

After reading the manual, readers should know and understand necessary requirements resulting from a sys-
tem configuration and integration. The integration primarily involves the interface description between the
components and the customer connections.
This project planning manual explains the most important guidelines according to which MTU Onsite Energy
systems are configured. However, no claim is made that the manual is complete. Regional and country-spe-
cific standards must be examined separately.
Further information
The project planning manual provides the target group with an initial overview of the complex area of project
planning. This manual therefore does not offer all of the information necessary to plan and implement a
project.
General information and drawings can be called up after registration on the MTU Onsite Energy homepage.
SpecSheets on the respective products are also available here.
Detailed and current information on MTU Onsite Energy products and planning or configuration is available in
the MTU Business Portal. The MTU Business Portal can be reached by MTU distributors and MTU service
partners under the following Internet address:
• http://partner.mtu-online.com/irj/portal
In the MTU Business Portal, you will also receive access to the following software and databases to support
you with configuration and application engineering:
• TEN database (Technical Evaluation Network)
• IPAS (Application Engineering Tool) (→ Page 21)
• HP-Spec (Power System Sizing and Specification Program) (→ Page 22)
Legal notes
This manual is designed as a basic support and refers to the special features of application engineering of
and with MTU Onsite Energy products. It is not intended to list and describe all details and process steps of a
concrete project. In this respect MTU Onsite Energy shall not guarantee the completeness, correctness and
up-to-dateness of the information and data contained in the manual. The information has been worked out
and compiled with the greatest possible care. Liability of MTU Onsite Energy for this, for whatever legal
ground, is excluded in all cases.
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1.2 Company presentation MTU Onsite Engergy
MTU Onsite Energy is one of the core brands of Rolls-Royce Power Systems AG – one of the world's leading
suppliers of high and medium-high speed diesel and gas engines, complete drive systems, decentralized en-
ergy systems and fuel injection systems for the most demanding requirements.
Together with MTU, MTU Onsite Energy, Bergen Engines and L’Orange, first-class energy and drive solutions
are developed at Rolls-Royce Power Systems AG. Irrespective of whether series production products or tai-
lor-made individual systems are called for, the solutions from Rolls-Royce Power Systems AG are amongst
the best on the market, and stand out clearly from others.
Figure 1: Portfolio of Rolls-Royce Power Systems AG
MTU Onsite Energy

Systems from MTU Onsite Energy ensure that energy is provided reliably, irrespective of the existing infra-
structure, at any time and in any place. The systems based on diesel and gas engines provide continuous,
standby and peak electricity, along with heating and cooling.
MTU Onsite Energy delivers complete system solutions for energy supply: from systems for standby power,
base-load and prime power supply through to high-performance cogeneration power plants. Furthermore,
MTU Onsite Energy offers a complete portfolio of service products that permit optimum and long-term use of
the systems.
MTU Onsite Energy developed as a system supplier from MTU Friedrichshafen. The timeline in the following
illustration shows the company's development.
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Figure 2: Company's development
MTU Onsite Energy as intelligent system provider:
• MTU Onsite Energy is the innovation leader for intelligent, decentralized energy systems with scope for
future expansion and a full range of technology and service solutions.
• With its tailor-made energy solutions, MTU Onsite Energy is at the cutting edge of technological develop-
ment.
• Our task: Providing electricity, heating and cooling in any place, at any time.
• Our drive: Efficiency through sustainable and tailor-made solutions for our customers.
The brand values of MTU Onsite Energy:
• MTU Onsite Energy stands for strength. We deliver high-performance, and we are both global and reliable.
• MTU Onsite Energy is a solution provider. We are flexible, close to our customers and we work with them
in a spirit of partnership.
• MTU Onsite Energy is an innovation leader. We are intelligent, open and fascinating.
• MTU Onsite Energy stands for sustainability. We are responsible, clean and trustworthy.
Sites
The headquarters of MTU Onsite Energy are located in Friedrichshafen (Germany).
Important sites for production and sales of Rolls Royce Power Systems and MTU Onsite Energy are listed
below:
• Diesel system production in Ruhstorf (Germany)
• Gas system production in Augsburg (Germany)
• Engine production in Aiken (USA) and Shenzen (China)
• Sales and production site for systems in Mankato, MN (USA)
• Sales hub for Asia in Singapore
• Sales and production location for medium-fast speed gensets in Bergen (Norway)
Key technologies and expertise

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As a system supplier, MTU Onsite Energy offers all key technologies and expertise for the development and
conception of standard systems as well as for complex individual solutions.
Diesel gensets
The depiction below shows the key technologies for high-speed diesel gensets and the most important core
competences.

Figure 3: Diesel gensets
Gas gensets and cogeneration power plants

Complete systems based on gas engines require expertise in areas listed in the following presentation.
Figure 4: Gas gensets and cogeneration power plants

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1.3 Product portfolio
MTU Onsite Energy is one of the world's leading suppliers of decentralized energy systems based on diesel
engines, gas engines and gas turbine technology.
The vast experience MTU Onsite Energy has in the development and production of power generation plants is
particularly evident in the custom-designed gensets. Such system solutions are adapted exactly to:
• the respective customer
• the specific operating area
• the individually environmental conditions
Special characteristics of the power generation systems from MTU Onsite Energy:
• Products for 50 Hz and for 60 Hz
• All conventional emission requirements (e.g. TA-air/TA-Luft, NEA, EPA)
• Operation with biogas, liquefied natural gas and liquefied propane (gas gensets)
• 75% average load factor for Prime Power applications
• 85% average load factor over 24 h with all Standby Power applications
• 100% average load factor over 24 h with all Continuous Power applications
• IBC certificate for earthquake protection and OSHPD certificate (diesel, only 60 Hz application)
The standard product portfolio is presented below; this is designed to meet most customers' requirements.
Figure 5: Systems for power and/or heat generation

The products from MTU Onsite Energy are divided into the following groups:
• Diesel gensets (high and medium-speed)
• Gas gensets (high and medium-speed)
• Power modules
• Power station
• Cogeneration power plant solutions
Diesel gensets
The following table shows the power ranges for diesel gensets from MTU Onsite Energy. Diesel gensets are
available for the typical application groups of standby power (ESP), continuous power (COP) and prime power
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(PRP) (This is not applicable to your system.). For more detailed information and technical data about the
individual gensets, refer to www.mtuonsiteenergy.com.
Diesel genset Power at 50 Hz Power at 60 Hz
0060 DS / 0080 DS / 0113 DS (low power range - 30 to 94 kVA 34 to 250 kVA
LPR) 24 to 122 kWe 27 to 200 kWe
1600 series 280 to 730 kVA 263 to 750 kVA
224 to 584 kWe 210 to 600 kWe
Configuration based on ISO 8528
MTU-internal reference conditions: Intake air temperature 25 °C, site altitude 400 m above sea level

Diesel genset Power at 50 Hz Power at 60 Hz
616 to 1032 kWe 615 to 1250 kWe
1240 to 2600 kWe 1125 to 3250 kWe
Configuration based on ISO 8528
MTU-internal reference conditions: Intake air temperature 25 °C, site altitude 400 m above sea level
Gas gensets
MTU Onsite Energy has decades of experience and extensive system expertise in development, application
engineering, production and support for complete systems based on gas engines.
Irrespective of what the requirement is, e.g. continuous, standby or prime power supply, straightforward
electrical power generation, cogeneration (combined heat and power, CHP) or trigeneration (combined cool-
ing, heat and power, CCHP), in all cases the gas gensets from MTU Onsite Energy represent an effective,
reliable solution that is configured precisely according to customers' requirements.
The following table shows the power ranges for gas gensets from MTU Onsite Energy.
Gas genset Power at 50 Hz Power at 60 Hz
Continuous power (natural gas) – 400 series 119 to 420 kWe 128 to 358 kWe
Continuous power (biogas and special gas) – 400 182 to 400 kWe 175 to 350 kWe
series
series
Standby power with natural gas or propane - 30 to 400 kWe
Prime power with natural gas - 130 to 355 kWe
Power modules (diesel genset)

Wherever electricity is required, mobile and stationary power modules from MTU Onsite Energy provide the
greatest possible flexibility. They are the perfect solution for construction sites, individual production opera-
tions or entire communities.
Power modules from MTU Onsite Energy are installed in a container (ISO shipping container) for easy trans-
port and straightforward use. They are characterized by economical fuel consumption, high reliability and op-
timized maintenance intervals. All connections for operating fluids can be accessed from outside.
Mobile power modules

Mobile power modules are available for the application group of prime power (This is not applicable to your
system.).
Mobile power modules Power at 50 Hz Power at 60 Hz
1600 series 350 kVA 688 kVA
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280 kWe 550 kWe

2000 series - 1000 kWe
1250 kVA
Stationary power modules

Stationary power modules are available for the application groups of standby power, continuous power and
prime power (This is not applicable to your system.).

Stationary power modules Power at 50 Hz Power at 60 Hz
1500 to 1900 kWe 1760 to 2160 kWe
Stationary power modules (gas gensets)

Wherever electricity is required, stationary power modules from MTU Onsite Energy provide the greatest pos-
sible flexibility. They are the perfect solution for construction sites, individual production operations or entire
communities.
MTU Onsite Energy power modules are characterized by economical fuel consumption, high reliability and
optimized maintenance intervals. All connections for operating fluids can be accessed from outside.
Stationary power modules Power at 50 Hz Power at 60 Hz
4000 series 1538 - 2030 kWe 1151 - 1272 kWe
Cogeneration power plants

A large share of energy during engine operation is lost due to waste heat. Cogeneration power plants from
MTU Onsite Energy store the heat energy via heat exchangers in the heating water network of the customer.
A cogeneration power plant thus produces not only electricity but also thermal energy. Refrigerating solu-
tions are also provided.
Cogeneration power plant solutions Natural gas Biogas and special gas
400 series 120 - 420 kW 190 - 400 kW
4000 series 770 - 2500 kW 763 - 1948 kW
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1.4 MTU Onsite Energy system business
Due to the wide range offered, the "gas" and "diesel" systems from MTU Onsite Energy are subdivided into
three different system areas:
• Series system business (SSB)
• Customer-specific system business (CSB)
• Project system business (PSB)
Figure 6: System business units
Series system business (SSB)

All series systems from MTU Onsite Energy are assigned to the area SSB. They are delivered in the desired
configuration. The installation and adaptations are the responsibility of the distributors and system integra-
tors. The main task is the delivery of the standard scope supplemented by previously defined options.
This business unit includes the following products:
• Diesel gensets (stand-alone)
• Gas gensets (stand-alone)
• Gas gensets + heat module
• Power module (stationary and mobile)
Customer-specific system business (CSB)

All systems from MTU Onsite Energy that have been specially adapted to customer requests are assigned to
the area CSB. The type and scope of the adaptations range from customized painting to special power
switches or generator configurations. All adaptations must be arranged with the customer and must comply
with all standards and directives.
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• Gas gensets + heat module
Tailor-made solutions
The flexibility of the product models means that standard delivery items can be modified and adapted. In
close corporation with the customer, MTU Onsite Energy develops individual customer adaptations. This
means all necessary customers' requirements can be met.

Example of possible adaptations to customers' requests
Diesel gensets
• Generator
Oversized generators with reserve thermal capacity, downtime heating, winding temperature sensors,
bearing temperature sensors, protective transformers for differential protection, digital voltage regulators
• Control
Broad range of control configurations for use in isolated operation and grid parallel operation of several
gensets. Expansion modules for a wide variety of requirements (e.g. analog and digital inputs and outputs)
• Fuel system
Fuel prefilter with water separator
• Cooler
Mechanical and electrical cooler fitted on a separate mounting frame for ambient temperatures of 40 °C
and 50 °C
• Exhaust system
Silencer with various damping levels
• Acoustic enclosures / container (mobile or stationary)
• Emissions
EPA Tier 23, emissions-optimized acc. to TAL, fuel-optimized
Gas gensets
• Generator
• Control
Broad range of control configurations for use in isolated operation and grid parallel operation of several
gensets. Expansion modules for a wide variety of requirements (e.g. analog and digital inputs and outputs)
• Cooler
Product-dependent. For detailed specifications, please contact MTU Onsite Energy.
• Exhaust system
Silencer with various damping levels
• Heat module
Energy recovery from engine coolant and exhaust gas via heat exchanger
• Container (stationary)
• Emissions
Emission-optimized according to TAL, fuel-optimized
Project-specific system business (PSB)

All project-specific systems from MTU Onsite Energy are assigned to the area PSB. This includes the com-
plete plant or parts thereof. Installation and adaptations are carried out together with the customer or a
third-party supplier.
• Power module (stationary and mobile)
• Power station
• Gas-operated cogeneration power plant
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1.5 Test conditions for engines and gensets
Objective test conditions by mobile and stationary test stand systems
A quality inspection and assurance acc. to ISO 9001 AQAP 4 is a significant factor in meeting the demanding
requirements on quality and configuration of MTU gensets. This is done for all component parts by running
the engine on the hydraulic dynamometer, through to testing the entire genset on the modern test stand
systems at MTU Onsite Energy. MTU Onsite Energy places high requirements on the quality and configura-
tion of its products. They are the preconditions for reliable and economical operation at the installation site.
Several test stands are available at every production location where a very wide variety of environmental
conditions and incidents can be simulated (e.g. outside temperature tests). The test stands can be used both
for the actual series final acceptance as well as for test programs in the framework of development projects
or product care programs. The available equipment depends heavily on the actual area of specialization at
the production location. Details on the respective locations can be provided upon request.
The direct current generator test stand is transportable and can also be used in customers' systems on-site.
The possibilities that MTU Onsite Energy can offer its customers are dealt with in detail below.
Standard end-of-line test for MTU Onsite Energy gensets

One of the most important tests is the end-of-line test after production. In this case, the complete genset is
subject to a final acceptance test. It is divided into a preliminary check and then the actual test run. During
the general preliminary check, the prepared genset is subject to the following tests, among others: Mechani-
cal and electric visual check, measurement of mechanical restraint device, filling and check of operating me-
dia, installation and parameterization of controller software and, if necessary, adjustment of contactors. The
genset is then run on the test stand and tested extensively according to the valid and approved MTU inspec-
tion instructions. The table below is an extract from a typical route card for the test run and clearly shows
the typical sequence of the end-of-line test.
Object of the test
Preliminary check of genset
Idle run / load run
• Switch-off checks
• Functional check
• Carry out load run
• Load switching (impact load)
Engine leak check
Preservation
Data backup
Table 1: Extract from route card

After test performance, the results are recorded on an acceptance record. A detailed description of all test
contents can be requested.
Customized Factory Acceptance Test

Apart from the standard end-of-line test, our customers can also request a special test run tailored to their
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requirements. It can take specific wishes into consideration and can also be carried out with direct customer
participation. However, such tests are strongly dependent on the actual customer's wishes and therefore de-
tailed consultation with MTU Onsite Energy Sales is required in advance.

1.6 Configuration planning
Consulting
Before an request for quotation is issued for an engine-generator set, intensive consultation must take place
between the end-user and the MTU project planner or MTU distributor, see general chapter Basic knowl-
edge - general and specific chapter Basic knowledge. The requirements and wishes of the end-user are
defined to list the options and advantages of the plants from MTU Onsite Energy, see specific chapter Cus-
tomer requirements.
In case of concrete interest or a request for quotation from the end-user, the request will be further process-
ed.
Request for quotation

In a request for quotation, the end-user defines the exact requirements of an engine-generator set or a com-
plete plant from MTU Onsite Energy. These requirement are communicated to the MTU project planner or
MTU distributor, see chapter Customer requirements.
The MTU project planner or MTU distributor checks the request for quotation and prepares a compliance
matrix between the customer requirements and the MTU standard scope of delivery so as to indicate dis-
crepancies. When doing this, it is necessary to differentiate between activities by MTU Onsite Energy and
activities to be carried out locally by distributors and project planners. All deviations from the MTU standard
scope of delivery must be identified for this purpose. Clarification is required as to whether the deviating
requirements are necessary and who is to be responsible for the implementation (series business vs. project
system business), see chapter Planning criteria.
Parallel to this the MTU project planner or MTU distributor creates a project with the project planning tool
IPAS, which helps to communicate a concrete offer to the customer and to track the order progress
(→ Page 21).
Order receipt and production

After the official order has been placed, the order is transferred into production. Here, the genset or the sys-
tem is produced according to the contractually defined specifications. The documentation for operation and
maintenance of this plant is also an element of the scope of delivery and is prepared by MTU Onsite Energy
during the production process.
During the course of production, all conditions for transport and delivery of the system to the customer must
be clarified. Specifically, these include import and export regulations and special transport and delivery con-
ditions .
Integration and commissioning

Integration and commissioning is carried out by the MTU project planner or MTU distributor, who ensures
that the plant functions correctly by checking the installation guidelines and instructions. Additional installa-
tion services are usually performed locally by the distributor.
Commissioning should be carried out by MTU-internal Service personnel or by an authorized and MTU-certi-
fied technician.
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1.7 CE conformity
Conformities of MTU Onsite Energy products
Products from MTU Onsite Energy are designed and built in compliance with Machinery Directive
2006/42/EC and other relevant EU guidelines. Depending on the scope of delivery for complete machines,
MTU Onsite Energy issues a CE Declaration of Conformity and provides it with a CE mark. For partly-complet-
ed machinery, a Declaration of Incorporation with appendix is issued, without a CE mark.
To determine all hazards associated with a product, MTU Onsite Energy carries out a Risk Assessment.
Through the introduction of suitable protective measures (risk minimization measures), dangers to humans
and environment are reduced to a minimum or eliminated completely.
Risks that may remain in certain circumstances (residual risks) and all important information on the safe
use / intended use of the machine are contained in the Operating Instructions and further customer docu-
mentation.
Integration of machines / pressure vessels / gas appliances in a complete plant

MTU Onsite Energy can only issue Declarations of Conformity or Incorporation for its own scope of delivery.
To determine possible safety-related interlinking between several machines / pressure vessels / gas appli-
ances etc., a higher-order risk assessment of the complete plant must be prepared. The manufacturer of the
complete plant is responsible for the preparation of the higher-order risk assessment, the implementation of
the higher-order safety concept derived from it and the Declaration of Conformity with CE mark.
Depending on the plant and installation of the machines, the following situations must be taken into account:
• Internal and external explosion
• Fire
• Ventilation concept
• Heat supply from cogeneration
• Biogas application
• Mechanical and electrical hazards
• Movement of plant or a part of the plant into safe state (including EMERGENCY STOP) and safeguarding
against unexpected start-up
The conditions listed are prerequisites for safe and trouble-free plant operation. Before the start of planning,
official specifications must already be researched and necessary approvals obtained. The requirements of
the building also apply, where applicable, to the container solutions. Documents to be used:
• Technical description
• Technical data sheet
• Foundation data sheet
• P&I diagram
• Planning drawing
• Fluids and Lubricants Specifications
• Component quality specification
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2 Basic Knowledge
2.1 Use of gensets
Gensets from MTU Onsite Energy meet all the challenges facing the energy supply:
• Individually tailored system solutions
• Autonomous or supplying solutions
• Optimum integration in existing infrastructure
• Maximum energy use by cogeneration power plant and heat recovery
• Variable electrical power supply for stabilizing the power grid
• Standby power, base load supply and peak load cover
MTU Onsite Energy offers a wide range of solutions. These are categorized and explained below, in order to
provide a rapid basis for deciding on the number and type of genset as well as the type of fuel.
Diesel gensets
Diesel gensets are used for generating electricity alone. As a result, the operating mode is only ever config-
ured according to the amount of electricity required. The operating modes are defined during the planning
phase (→ Page 37):
• Independent from the power grid – isolated operation (with several gensets: isolated parallel operation)
• For supporting the power grid – grid parallel operation
• As a replacement for the power grid – standby power operation (standby genset)
Gas gensets
MTU Onsite Energy gas gensets can be design both for power generation alone or also as cogeneration pow-
er plants for heat recovery.
MTU Onsite Energy gas gensets are designed such that they can convert different types of gas into energy.
Cogeneration power plants

Cogeneration power plants use not only the electrical energy of the generator but also the thermal energy of
the engine and the exhaust gas. This thermal energy is supplied to the customer as heated water. Other
methods of operation therefore also have to be defined during the planning phase:
• Heat-controlled
• Current-controlled
• Combined
• Mains-controlled
In a heat-controlled cogeneration power plant, the power output is based on the customer's heat require-
ment. The generated electricity is either used by the customer itself, or is fed into a public power system
(→ Page 39). This usage type is most commonly found in single or multi-family dwellings and in commercial
companies. Cogeneration power plants configured for heat control can be operated more economically be-
cause short-term fluctuations in the current demand are irrelevant. During configuration, it is necessary to
decide whether the cogeneration power plant should be operated on the basis of peak or base load
(→ Page 59).
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In a current-controlled cogeneration power plant, the power output is based on the customer's electricity
requirement. The heat generated can not be output directly, which means it must either be dissipated un-
used or stored in buffer accumulators. This type of use chiefly occurs in isolated power systems that operate
autonomously from the public power grid (→ Page 37). The second scope of application is in biogas systems
because these feed in all the electricity they produce in order to earn payment.
18 | Basic Knowledge | E 2015-08

The power output of a cogeneration power plant with combined control is oriented towards the customer's
electrical base load and thermal base load. This means a maximum capacity utilization of the cogeneration
power plant is achieved. Usually, a second cogeneration power plant is connected as well to cover peak
loads. This type of use is attractive for hospitals and various areas of industry. However, with gas gensets,
particularly when used in hospitals and similar buildings, the longer starting time in comparison with diesel
gensets must be noted.
With a mains-controlled cogeneration power plant, the power level (power requirement) for several plants is
specified by the network operator (→ Page 37). The plant is therefore not autonomous, but rather switched
on and off according to the requirements of the network operator. The core idea behind this grouping of sev-
eral cogeneration power plants to a "virtual power station" is to make the grid network more flexible and, at
the same time, more stable. It is thus easier to compensate for feeders such as wind and solar plants from
the grid network.
Pure electricity generation

For gas gensets used exclusively for current generation, the operating mode must always be designed ac-
cording to the required amount of current only. They can be used in different ways, which have to be defined
during the planning phase (→ Page 37):
• Independent from the power grid – isolated operation (with several gensets: isolated parallel operation)
• For supporting the power grid – grid parallel operation
• As a replacement for the power grid – standby power operation (standby genset)
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E 2015-08 | Basic Knowledge | 19

2.2 Comparison between diesel genset and gas genset
The following table should clarify the difference between diesel and gas gensets. The presentation serves as
an example.
Description Diesel genset Gas genset
Principal application groups 3B and 3D: 3A:
• Emergency power system: If • Use as cogeneration power
there is no power system or in plant in grid parallel operation
case of a power failure • Also sometimes as emergency
3E: power system if there is a
• Emergency power system with power failure
overload capability (10%): If
there is no power system or in
case of a power failure
3A rare:
• Power plant grid parallel opera-
tion with continuous electricity
generation for base load
Grid parallel operation Chiefly in the area of power plant In most cases, the genset is run
operation (3A) or for grid support in grid parallel operation.
(minute reserve).
In emergency power systems,
back-synchronization is frequently
used in order to switch between
the power system and genset with-
out interruption when the grid pow-
er returns. However, grid parallel
operation only takes place for very
short periods here, so this is not re-
garded as grid parallel operation in
the full sense of the expression.
Cogeneration Extremely rarely Main application
Ramp-up time / interruption time < 10 s for NFPA110
Load imposition approx. 60% - 100% in the first
stage (product-dependent)
Typical performance classes (DIN G2, G3 (This is not applicable to G1, G3 (→ Page 47)
ISO 8528-5) your system.)
Typical frequency settling times G2 = 5 seconds G1 = 10 seconds
G3 = 3 seconds G3 = 3 seconds
Typical voltage settling times G2 = 6 seconds G1 = 10 seconds
G3 = 4 seconds G3 = 4 seconds
Typical frequency deviation on load G2 = -10% G1 = -25%
imposition G3 = -7% G3 = -15%
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Typical voltage deviation on load G2 = -20% G1 = -25%

imposition G3 = -15% G3 = -15%
Fuel supply Autonomous supply from fuel tanks Supply from an existing gas con-
nection
An autonomous supply with nat-
ural gas or liquefied propane, for
example, is possible in special
cases.
NFPA 110 compliant Yes No

2.3 IPAS application engineering tool
IPAS is an integrated application system that provides the best possible support for the global processes of
quotation preparation and order handling through a very wide range of functions. As a central tool for project
data updating and quotation preparation or order handling, IPAS supports not only RRPS users but also the
external partners in the area of finished products. IPAS aims to be the central application system for all appli-
cations, products, regions, factories and selling processes and to represent all business transactions from
standard business to complex system business. This integration makes it possible for RRPS and thus the
customer, partners and colleagues:
• To define and update the product and configuration data for all products and factories in a central area
• To access all products and factories in a single system
• To work continuously with an identical job and ordering process for all products / regions / factories
• In case of an order, to communicate automatically via interfaces the relevant information to the individual
production systems (e.g. SAP PS3 and MS5) at the various locations.
• To receive comparable management information for all products / regions / factories
IPAS basic data

The preparation and updating of basic data from IPAS takes place centrally in close cooperation with the
participating specialist departments at TRCD. Apart from the basic data of the product models, the Product
Catalog and the displayed commercial conditions, among other things, are also updated here.
IPAS reporting
IPAS reporting provides detailed management information on the IPAS projects. Various standard reports of-
fer an overview of the sales activities in IPAS.
IPAS Support
If you have any questions about IPAS or concrete application cases, the IPAS Hotline is available from Mon-
day to Friday in Friedrichshafen (8:00-17:00 CET) and Novi (7:00-15:30 EST). The Hotline can be reached
under the following address:
• Friedrichshafen: IPAS_Support@mtu-online.com
• Novi: IPAS-Support-America@mtu-online.com
• Phone: +49 7541 90 3777
IPAS Academy
Furthermore, the IPAS Academy at TRCD offers a very wide variety of user training courses from a basic in-
troduction to intensive training. If you are interested, please contact the IPAS Hotline to receive information
on the current training dates. The current training dates are also included in the IPAS Newsletter.
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2.4 Rating program HP-Spec (Power System Sizing and
Specification Program)
The MTU in-house program HP-Spec is designed for project planners, service providers and other specialists
involved in planning, analysis and configuration of an engine-generator set or a complete plant. The program
is suitable, above all, for the configuration of diesel gensets because they have to react quickly to a very wide
variety of load requirements.
HP-Spec uses many different parameters to calculate the optimum genset and the correct electrical connec-
tions. The graphic user interface provides a clearly arranged presentation and step-by-step instructions.
Input of ambient conditions (selection):
• Site altitude
• Ambient temperature
• Country selection
Input of basic requirements of the genset (selection):
• Frequency
• Product type
• Voltage
• Fuel type
• Application group
• Temperature range
• Detailed input of load stages and loads
The calculated parameters can be saved and output in many different formats.
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3 Application engineering for gas gensets
3.1 Basic Knowledge
3.1.1 Referenced documents and standards
The document makes a reference to the following listed documents and standards.
Referenced documents
Gas genset
Document number Title
DK-BS-0001 MTU Fluids and Lubricants Specifications for 400 series
DK-BS-0002 MTU Fluids and Lubricants Specifications for 4000 series
Referenced standards and directives

The following list of standards, directives and regulations makes no claim to be complete.
Standards and directives
ISO 8528-1 Power gensets with reciprocating internal combustion engines- Part 1: Applica-
tion, ratings and versions
ISO 8528-5 Power gensets driven by reciprocating internal combustion engines - Part 5:
Power gensets
ISO 8528-13 Power gensets driven by reciprocating internal combustion engines - Part 13:
Safety
ISO 3046 Reciprocating internal combustion engines - requirements
ISO 4200 Plain end steel tubes, welded and seamless; general tables of dimensions and
masses per unit length
IEC 60034-5 Rotating electrical machines - Part 5: Classification of protection degrees pro-
vided by the integral design of rotating electrical machines (IP code)
IEC 60034-7 Rotating electrical machines - Part 7: Classification of types of construction,
mounting arrangements and terminal box position
IEC 60034-22 Rotating electrical machines - Part 22: Reciprocating internal combustion en-
gine-driven alternating current generating sets
DIN VDE 0100-430 Low-voltage electrical installations - Part 4-43: Protective measures against
overcurrent
DIN VDE 0100-520 Low-voltage electrical installations - Part 5-52: Selection and installation of elec-
tric equipment - cable and line installations
DIN VDE 0100-540 Low-voltage electrical installations - Part 5-54: Selection and erection of electri-
cal equipment - grounding arrangements and protective conductors
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DIN VDE 0100-729 Low-voltage electrical installations - Requirements for special installations or lo-
cations - Part 729: Operation and maintenance aisles
DIN VDE 0100-731 Low-voltage electrical installations - Requirements for special installations or lo-
cations - Part 731: Closed electrical premises
DIN VDE 0298-3 Use of cables and insulated lines for power plants - Part 3: Guidelines for use in
non-harmonized power installations
DIN VDE 0298-4 Use of cables and insulated lines for power plants - Part 4: Recommended val-
ues for the current carrying capacity of cables and lines for permanent installa-
tion in and on buildings and of flexible lines
E 2015-08 | Application engineering for gas gensets | 23

Standards and directives
DIN 4807 Expansion tanks
DIN 6280-13 Power gensets with reciprocating internal combustion engines - Part 13: For
emergency power supply in hospitals and in public buildings
DIN 6280-14 Power gensets with reciprocating internal combustion engines - Part 14: Cogen-
eration power plants (CPP) with internal combustion reciprocating piston en-
gines; basic principles, requirements, components, design and maintenance
DIN 6280-15 Power gensets driven by reciprocating internal combustion engine - Part 15: Co-
generation power plants (CPP) with internal combustion reciprocating piston en-
gines; Tests
DIN 6624 Horizontal single-wall steel tanks with capacities between 1000 and 5000 liters,
for the above ground storage of flammable and non-flammable water polluting
liquids.
DIN 6625 Angular steel tanks for above ground storage of liquids with a flashpoint of more
than 55 °C
DIN EN 10220 Seamless and welded steel tubes - Dimensions and masses per unit length
DIN EN 10305-1 Steel tubes for precision applications - Technical delivery conditions - Part 1:
Seamless cold drawn tubes
DIN EN 12261 Gas meters - Turbine gas meters
DIN EN 50565-1 Electric cables - Guide to use for cables and insulated lines with a rated voltage
not exceeding 450/750 V (U0/U) - Part 1: General guidance
DIN EN 50565-2 Electric cables - Guide to use for cables and insulated lines with a rated voltage
not exceeding 450/750 V (U0/U) - Part 2: Specific guidance related to EN
50525 cable types
DIN EN 60079-14 Explosive atmospheres - Part 14: Electrical installations design, selection and
erection
DIN EN 60228 Conductors of insulated cables
DIN EN 60617-6 Graphical symbols for diagrams - Part 6: Production and conversion of electrical
energy
DIN EN 61558 Safety of power transformers, power supplies, reactors and similar products
DIN EN ISO 7010 Graphical symbols - Safety colors and safety signs - Registered safety signs
ANSI Z535 American National Standards Institute - system for presenting safety and acci-
dent prevention information
TRbF Technical Regulations for Combustible Liquids
For further standards related to cabling, see (→ Page 145).

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3.1.2 General conditions
At the start of planning, the general conditions under which the genset should operate must be defined as
precisely as possible. The most important parameters that should be clarified with the customer at the start
of a project are stated below.
The following general conditions must be discussed with the customer regarding configuration of gensets for
generating electricity or heat:
1. Operating modes and methods
2. Consumer types
3. Power requirements
4. Ambient conditions
Operating modes
In advance, clarify with the customer in what operating mode the genset(s) should be operated. Basically, it
is possible to differentiate between isolated operation and grid parallel operation.
In grid parallel operation, there is a high frequency stability due to the large number of power plants from
which the supply is drawn. As a result, engines in grid parallel operation are normally not exposed to abrupt
load changes.
In isolated operation, the genset must follow the changing load requirements of the loads. This means en-
gines for electrical power gensets are exposed to significantly higher and more abrupt load changes.
MTU Onsite Energy engines, gensets and systems not only meet the described requirements, but also offer
low maintenance costs and high safety standards.
Operating methods
In advance, clarify with the customer in what operating method the genset(s) should be operated. Basically, a
distinction can be made between current-controlled, heat-controlled or standby power operation. The re-
spective operating method is of definitive importance for selecting the type of engine-generator set.
Consumer types (loads)

For planning purposes, particularly in isolated operation, it is necessary to know in advance which and how
many loads will be imposed on the genset.
In addition, it is necessary to clarify the number of stages in which the load should be switched to the gen-
set.
Properties of electricity or heat/cooling load

For correct planning, first check and determine the power properties for electricity (→ Page 28) and, in the
case of a cogeneration power plant, the power properties for heat (→ Page 33).
Following this, the properties and specialties of the current loads must be established when using electrical
power gensets (→ Page 50).
When using cogeneration power plants, the heat or heat/cooling consumption must also be determined
(→ Page 59).
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Switch-on power
Once the load has been established, it is necessary to define whether this load should be switched to the
genset in one or several stages.

The following scopes of application are differentiated acc. to DIN 6280-13 (This is not applicable to your sys-
tem.):
• For scope of application 1 (acc. to DIN VDE 0100-710 for hospitals):
80% of the entire load power must be provided following a switchover time of max. 15 s.
100% of the total load power must be made available in max. 2 stages and after a further 5 s.
• For scope of application 2 (acc. to DIN VDE 0100-718 for public buildings):
100% of the load power of the necessary safety devices must be provided following a switchover time of
max. 15 s.
The operational limits for electrical power gensets must at least correspond to scope of application 2 acc. to
DIN 6280-13.
Power requirements
The requirements that must be met by the genset in order to meet the customers' requirements are defined
below as power requirements of the genset.
Interruption time / switchover time

An important parameter for electricity supply systems is to achieve an interruption time in the electricity sup-
ply that is acceptable for the customer. This applies above all to plants in standby power operation.
The interruption time is defined as the period between mains failure and correct supply of the load by the
genset (DIN 6280-13):
• standby power genset with a defined switchover time of max. 15 s
• short-break genset with a switchover time of up to 0.5 s
• no-break genset without switchover time
Gensets for the American market must comply with the standards NFPA 110 and NEC 700-708. Depending
on the application, an uninterruptible power supply (UPS) can be installed (This is not applicable to your sys-
tem.).
Performance class
The performance class of a genset specifies the "quality" of the voltage and frequency behavior of the gen-
set. The customer's quality requirements must be precisely defined at the start of project planning.
DIN ISO 8528-5 defines four performance classes, G1 to G4, in which operational limits with regard to volt-
age and frequency behavior are listed (→ Page 47).
The scope of application and requirements must be defined precisely with the customer, because there are
some discrepancies between DIN 6280 and DIN ISO 8528.
• G1: Low requirements on voltage and frequency behavior (lighting, simple drives)
• G2: Requirements on voltage and frequency behavior largely correspond to the public power system (do-
mestic appliances, fans, elevators)
• G3: Higher requirements on voltage and frequency behavior and on the waveform (telecommunications
equipment)
• G4: definable requirements between customer and supplier
Ambient conditions and infrastructure

For application engineering, it is necessary to know where the genset will subsequently be used.
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Check whether the engine meets the environmental conditions applicable at the installation site in its stand-
ard configuration.
Primarily, these are:
• Intake air temperature
• Site altitude
• Exhaust emissions requirements
• Noise emissions requirements
• Gas properties
• Further influencing factors on power (→ Page 65)

If the environmental conditions exceed the standard configuration values for the genset, the possible opera-
tional power must be determined using reduction factors. For gas engines in the 400 series, reduction fac-
tors are shown on the identification plate. Exact reduction factors for gas engines in the 4000 series are
available from MTU Onsite Energy.
Apart from the environment, the available infrastructure into which the genset has to be integrated plays an
important role.
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3.1.3 Power properties – Electrical power
A gas engine-generator set consists of an engine and a generator. Each component has its own characteris-
tics. As a system, these characteristics have a significant influence on the power and dimensions of the gen-
set.
The configuration of an engine-generator set for electricity production depends on the operating mode
(→ Page 37).
The electrical operational limits depend on whether operation is on a power grid or as a standby power gen-
set.
Due to the comparatively low power from the power grid, standby power gensets deliver different and/or
highly fluctuating voltage, frequency and harmonics (of the voltage). Changes in loads in standby power gen-
sets can result in voltage changes of 20%.
Generally speaking, it is first necessary to establish the magnitude of the parameters that are influenced by
the system, or the number and type of loads, both when planning a power grid and a standby power genset.
The following questions must be considered, for example:
• Can harmonic currents from rectifier systems damage downstream devices?
• Does the genset have to supply ohmic, inductive or capacitive loads?
A power calculation and configuration of the genset are determined by many factors (→ Page 57).
Once these general conditions have been defined, the performance class acc. to DIN ISO 8528-5 can be de-
fined (→ Page 47).
As the next step, the switchover times required by the customer are defined. With high-speed and no-break
gensets, note that these versions are extremely energy and maintenance-intensive because the generator
has to be driven continuously to compensate for a mains failure as quickly as possible.
It is also necessary to clarify the permitted static operational limits. Connecting complex machines together
makes it impossible to keep the specified power values of the components constant; rather, they fluctuate
about a mean value. The prescribed limit values are summarized in DIN ISO 8528-5 and must be complied
with.
The static operational limits are supplemented by dynamic limit values, which occur during load changes, for
example. The prescribed limit values are summarized in DIN ISO 8528-5 or DIN ISO 8528-13 and must be
complied with.
Fundamentals of alternating current

In alternating current, a phase shift (lagging and leading) between current and voltage is referred to. The
magnitude of the shift is specified by the cos φ. As a rule, the cos φ is referred to as the power factor (see
illustration below). If no further information is available, a cos φ of 0.8 is usually assumed for three-phase
generators.
There is a phase shift of 90° between the active power (P) and the reactive power (Q). The power triangle
illustrates the relationships.
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Figure 7: Alternating current
1 Current 2 Voltage
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Figure 8: Power triangle

In practice, the load is a mixture of incandescent lamps (cos φ = 1), electric motors and transformers, etc.
(cos φ = 0.65 to 0.8). The mixture of active and reactive current is referred to as apparent power. There is
only a division into active and reactive power at the particular prevailing cos φ of the shift angle.
The cross-sections of cables, lines and switch sizes are calculated based on the apparent current. The drive
power of a generator is determined by its active power output, however.
The total power in the alternating current circuit is the apparent power (S).
The active portion is referred to as the active power (P).
The reactive component of the power is referred to as the reactive power (Q).
Apparent power
The generator must be configured for the apparent power (S), i.e. in addition to the active power (P) also for
the additional reactive load requirement that is determined by the load.
The apparent power is a rating factor for quantifying the loading on the electrical system. The apparent pow-
er is specified in the data sheet or the technical documentation of the genset. The dimensions of circuit
breakers and protection systems for busbars must be set according to the apparent power.
The apparent power (S) is the product of the voltage (U) and current (I), and is calculated from the active
power (P) and the reactive power (Q):
• S = √(Q2 + P2).
• S = U xI
Effective power output

The active power (P) is the power that is available to be converted into other powers (e.g. electrical, mechan-
ic or thermal). It is necessary to differentiate it from the reactive power which can not be used for this con-
version.
The active power (P) is calculated from the apparent power (S) and the power factor cosφ, and is specified in
watts:
• P = S x cosφ
• P = U x I x cosφ
Reactive power
The reactive power (Q) is used on the load side for establishing a magnetic field, for example for operating
electric motors or pumps. Reactive power is drawn from the supply system, but is then fed back into the
power system with a time offset; in this way, it oscillates between the load and the producer.
This additional load means the dimensions of the power systems have to be made larger so as to accommo-
date not only the provided active power but also the oscillating reactive power.
Power factor (cosφ)

The power factor (cosφ) determines the ratio between required active power (P) and apparent power (S), and
is a measure of the available reactive load component of the load.
The power factor cosφ is the ratio between active power (P) and apparent power (S). It is calculated by the
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following formula:
• cosφ = P/S
Generator efficiency
The generator efficiency (ɳ) is a measure for the power loss of the generator that arises due to heat and
friction in the generator.
The efficiency (ɳ) of an electric generator is the ratio between the output power Pout and the supplied power
Pin
• ɳ = Pout / Pin

Small generators up to approx. 10 kVA have a relatively low efficiency level (ɳ = approx. 0.75) because the
mechanical friction losses and electrical scattering and iron losses are relatively high.
Medium-size generators have an efficiency of approx. 0.85.
Large generators can reach an efficiency level of up to approx. 0.97 at cos φ.
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3.1.4 Key planning parameters – Electrical power
Rated power
The rated power is the maximum required power (Pmax) of the generator. It is calculated by adding together
the power consumption of all installed loads (Pinst), and multiplying this by a simultaneity factor (g) that is
applicable to the overall system.
Pmax = Pinst x g
In addition, the characteristics of individual loads must be considered. The following are of particular impor-
tance:
• Starting currents of asynchronous motors
• Starting currents of transformers
• Load with recuperation possibility, e.g. elevators with braking devices incorporating generators
• Harmonic currents of consumers with nonlinear voltage-current ratio, e.g. rectifiers, frequency converters,
energy-saving lamps, switch mode power supplies, etc.
Each of these loads should be considered separately if their maximum operating current, either individual-
ly or in total (energy-saving bulbs), makes up more than 10% of the generator's rated current.
Simultaneity factor
The simultaneity factor (g) specifies what percent of the installed power will be needed simultaneously in
operation.
The simultaneity factor takes account of the situation that not all devices in an electrical system will be
switched on simultaneously and operating at full power. The simultaneity factor is generally based on experi-
ence, and so it can only ever be taken as a guidance value.
In spite of empirical values that might be available, it is important to establish which systems and equipment
are switched on at the same time. Also, the organizational sequence of operations as well as times of day
and seasons should be included in the overall considerations. The power provided must take account of the
most unfavorable case, i.e. the highest energy requirement that can occur simultaneously at any given time.
The simultaneity factor must be defined by the planner or customer taking account of any possible subse-
quent expansion.
Objective power requirement

For engine-generator sets in isolated operation, the objective power requirement is specified by the input
power of the loads to be supplied.
For peak shaving gensets, the power demand is derived from the difference between the max. mains power
demand and the main reserve capacity.
When determining the power demand, the intrinsic consumption for the supply of the genset-related auxiliary
drives (e.g. cooler fan, fuel pumps, etc.) required for operation of the engine-generator set must be taken
into consideration.
Interruption time / switchover time

The time between the start of the malfunction and complete restoration of supply by the genset. In this case,
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a differentiation is made between:

• defined switchover time: max. 15 s (depending on operating mode)
• defined switchover time: > 15 s (depending on operating mode)
• Rapid readiness: Interruption duration of a matter of milliseconds
• Immediate readiness: no interruption
Load stages
The released load stages are based on the ISO 8528 – 5 standard and apply to defined frequency dips and
spikes during load imposition or load shedding.
Further information on load stages, load imposition and load profile can be found here (→ Page 50).

3.1.5 Power properties – Thermal power
Heat power properties
Apart from the electric power, a cogeneration power plant also supplies thermal power (thermal output). In
order to utilize this power, the heat energy must be passed on to a heat exchanger. In modern cogeneration
power plants, the heat energy is not only recovered from the coolant and lube oil, but also from the exhaust
gas. A special heat exchanger is required to do this. The difference between the two cooling systems is that
the medium passing on heat in one case is a fluid and in the other case a gas. However, the parameters for
rating the thermal energy are basically the same.
The configuration of an engine-generator set for heat generation depends on the operating mode
(→ Page 39).
Thermal output Q
An engine passes on a thermal output (Q). This thermal output is created during the combustion of fuel in the
engine. A part of the thermal output is dissipated via lubricant or coolant and can be utilized by heat ex-
changers.
Q = m * cp * ΔT
• Mass flow m
Mass flow refers to the mass of a medium (coolant) that moves in a particular time frame through a cross-
section (the pipe, heat exchanger, engine block). The mass flow is specified in kilograms per second. In
the case of slow flows, also per minute or hour.
In practice, however, the mass flow is not usually used, but rather the volume flow V. To convert the mass
flow m into the practice-related volume flow, you require the density ρ of the medium. Then use the equa-
tion: m = ρ*V.
• Specific heat capacity cp
The specific heat capacity c describes how much energy a medium can store. Guide value: Water has a
heat capacity of 4200 J/kg * K. The technical documentation uses the reference values, e.g. for pure wa-
ter 1.145 kWh/m3 * K and for 35% glycol/water mixture 1.07 kWh/m3 * K.
• Temperature difference ΔT
This value specifies the temperature difference between the heating water supply and return line
Heating load
The heating load is a further important parameter for the determination of the power properties and is de-
rived from the heat losses in the room/building and the targeted temperature.
Cooling energy power properties

If an engine-generator set is used for cooling energy generation, the power properties of the cooling energy
generation must be determined.
The configuration of an engine-generator set for cooling energy generation depends on the operating mode
(→ Page 43).
Particularly in the summer months, by means of the absorption method the heat energy can also be used as
a refrigerant. An all-year refrigerant supply, e.g. for cooling systems, is also possible.
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Heat ratio
If an absorption chiller is used for cooling energy generation, the heat ratio is an important parameter for
determining the power properties. The heat ratio (ζ) is the quotient from the cooling capacity at the evapora-
tor and the thermal output at the generator.
Cooling load
The cooling loads is a further important parameter for determining the power properties. The cooling load KL
is calculated from the sum of all internal and external heat sources.

3.1.6 Application groups – Gas genset
MTU Onsite Energy gas gensets are divided into the following three application groups. Note that the gensets
from production in Augsburg are designed for continuous operation and gas gensets from Mankato (MN,
USA) are usually intended for peak and standby power applications. The difference can be explained mainly
by the different target market and gas engine used. Gas gensets for continuous usage power normal use gas
engines without overload capacity. This is in line with the ICFN classification acc. to ISO 3046-1.
• Continuous operation with maximum load – Continuous Power (COP) The engine-generator set is run at a
constant load without a time limitation. Example: Providing a base load for a cogeneration plant.
Continuous operation with variable load – Prime Power (PRP) The engine-generator set is run at a variable
electrical load without a time limitation. Example: Provision of electrical power as a substitute for the pub-
lic power grid.
Limited-time operation with variable load – Emergency Standby Power (ESP) The engine-generator set is
used for a limited time with variable electrical load. Example: To support the electrical power supply to a
building if there is a failure in the regular power supply.
Continuous Power – 3A
Description Load profile
Main application area:
• Power plant operation
• Continuous electricity generation for base load
• Part of an electricity supply or the public power
system
Expected operating hours:
• Min. 6000 h/a
• Average 7500 h/a
Grid operation type:
• Isolated operation
• Parallel operation
• Grid parallel operation
Definition: t Time
• Load: Continuous power with 100% load, without P Power
overload capacity (ICFN)* a Continuous power (100%)
• Load factor**: ≤100%
• Max. operating hours per year: Unlimited
Performance class***:
• G1 (G2 – G4 acc. to customer's requirement) TIM-ID: 0000055276 - 002

Prime Power – 3B
• Continuous electricity generation if no other elec-
trical power supply or public power system is
available
• < 5000 h/a
• Both
Definition:
• Load: Variable load, 10% overload capability
(ICXN)*
• Max. operating hours per year: Unlimited
• G3 acc. to normal conditions t Time
P Power
a Prime Power (100 %)
b Permitted average power over 24 h (Ppp)
c Actual average power over 24 h (Ppa)
d Stop
Prime Power Limited – 3C

• Emergency power supply
• Max. 1000 h/a
• Both
Definition:
• Load: Variable load, 10% overload capability
(ICXN)*
• Max. operating hours per year: 1000 h
• G3 acc. to normal conditions
t Time
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P Power
a Emergency power supply (100%)
b Permitted average power over 24 h (Ppp)
c Actual average
d Stop
* Declaration of power
ICXN – ISO power, continuous power, overload capacity
IFN – ISO power, blocked
ICFN – ISO power, blocked, continuous power

Codes for declaration of power acc. to ISO 3046-1
Declaration of power
I ISO power
S Service power
Power application
C Continuous power (continuous power)
F Fuel stop power (fuel stopp power)
O Overload capacity (overload power)
Power type
B Brake power with all auxiliary systems
N Brake power only with the essential auxiliary systems
In engines for continuous power (C) with overload capacity, this is specified with (x) and the % value of the
overload capability, e.g. ICXN, 5% overload capacity.
** Load factor
Arithmetical mean value of the power output over a 24 h cycle
*** Performance class

acc. to ISO 8528-5, min. customer requirement
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3.1.7 Basic Operations
3.1.7.1 Mains operation

Electrical power gensets provide electrical power. They can be operated as follows:
• Independently from the public power grid – isolated operation and isolated parallel operation
• For supporting the public power grid – grid parallel operation
• As a replacement for the public power grid – standby power operation (standby genset)
The mains operating modes define the behavior of one or more gensets in relation to the power grid.
Isolated operation
Description Line diagram
A genset only runs in isolated operation and does
not have a power system connection.
The power is determined by the imposed loads (load
management required).
Frequency (e.g. 50 Hz) and voltage are controlled.
1 Engine-generator set
2 Generator circuit breaker
3 Load stages
Isolated parallel operation

At least two gensets are connected via a common
busbar and run in isolated operation. They do not
have a power system connection.
The power is determined by the imposed loads (load
management and load division between gensets re-
quired).
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1 Genset
3 Load stages
E 2015-08 | Basic Operations | 37

Operation linked to the distribution network
One or more gensets run connected to the public
power grid following synchronization.
The power and cos φ are controlled externally.
The voltage and the frequency are specified by the
power system.
3 Power system
Standby power operation

One or more engine-generator sets switch to stand-
by power operation/standby power if there is a tem-
porary failure of the public power grid.
The power is determined by the imposed loads.
Standby power operation is run as "isolated opera-
tion", although it can also be operated as "grid paral-
lel operation" for a short time with feedback syn-
chronization. Please note that only short grid parallel
operation does not count as grid parallel operation,
and the system operator does not have to noti-
fied.Local regulations must be checked.
3 Grid
4 Mains circuit breaker
5 Load stages
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38 | Basic Operations | E 2015-08

3.1.7.2 Cogeneration – Gas genset
Engine-generator sets operated as cogeneration power plant modules consist of an engine/generator unit
with associated heat exchangers. A cogeneration power plant can always consist of one or more cogenera-
tion power plant modules.
The thermal energy generated by a cogeneration power plant can be obtained at the following points using
heat exchangers:
• Mixture cooler
• Lube oil cooler
• Engine coolant cooler
• Exhaust color
Configuration according to thermal base load requirement
Figure 9: Cogeneration power plant with peak load boiler

1 Supply 4 Heat accumulator 7 Cogeneration power plant
2 Peak load boiler 5 Electrical current for load or module(s)
3 Load public power system 8 Gas supply
6 Return
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Due to the high investment costs, a cogeneration power plant is operated economically if the highest possi-
ble number of operating hours are achieved. These systems are operated bivalently because they are com-
bined with a second heating system which provides support during peak times.
The thermal energy generation is only configured based on the thermal base load requirements of the load,
because the requirement for thermal energy is often subject to significant seasonal fluctuations, and other-
wise the cogeneration power plant module would have to be shut down. The base load requirement is the
requirement for thermal energy that is never undershot during one day. The base load requirement is calcu-
lated using the annual load duration curve and ordered annual load duration curve (→ Page 59) .

Heat accumulators make it possible to compensate for short-term load peaks and load troughs on the con-
sumer side (usually in the course of the daily heat requirements), while the cogeneration power plant oper-
ates at constant output.
Surplus heat from the cogeneration power plant module is stored in the heat accumulator, and taken from it
again if required.
The remainder of the required energy is provided by peak load boilers (gas or oil-fired boilers). This ensures
that the facilities are utilized more effectively, and achieve higher operating hours. The annual operating
hours of a cogeneration power plant module should be at least 5,000 to 6,000 hours.
The boiler is automatically started or stopped if the temperature has violated various upper or lower limit
values. The limit values for selection/deselection can additionally be shifted based on the outdoor tempera-
ture or a reduction.
The generated electrical energy can be used by the load itself, or supplied to the public power system.
Configuration according to thermal minimum requirement
Figure 10: Cogeneration power plant with peak load boiler and base load boiler
1 Supply 4 Consumer 7 Return
2 Peak load boiler 5 Heat accumulator 8 Cogeneration power plant
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3 Base load boiler 6 Electrical current for con- module(s)

sumer or public power sys- 9 Gas supply
tem
If, for various reasons, it is not possible to select a size which will cover the entire base load requirement, it
is possible to install a base load boiler. Base load boilers can be used if the heat from the cogeneration pow-
er plant module is not sufficient to provide the base load proportion.
The base load requirement is the requirement for thermal energy that is never undershot during one day. The
base load requirement is calculated using the annual load duration curve and ordered annual load duration
curve (→ Page 59).

Heat accumulators make it possible to compensate for short-term load peaks and load troughs on the con-
sumer side (usually in the course of the daily heat requirements), while the cogeneration power plant oper-
ates at constant output.
Surplus heat from the cogeneration power plant module and base load boiler is stored in the heat accumula-
tor, and taken from it again if required.
The boilers are automatically started or stopped if the temperature has violated various upper or lower limit
values. The limit values for selection/deselection can additionally be shifted based on the outdoor tempera-
ture or a reduction.
The generated electrical energy can be used by the consumer itself, or supplied to the public power system.
Configuration according to total thermal load requirement
Figure 11: Cogeneration power plant without peak load boiler

1 Supply 4 Electrical current for con- 7 Gas supply
2 Consumer sumer or public power sys-
3 Memory tem
5 Return
6 Cogeneration power plant
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module(s)
Small cogeneration power plant modules for residential buildings can also be operated monovalently, which
means they are the only heat source and cover the entire heat requirement. There is no peak load boiler in
this case.
Such a cogeneration power plant module is configured according to the peak load like a conventional heating
system. In a configuration of this kind, the cogeneration power plant module is switched off if no hot water is
required for heating or process water.
Short-term fluctuations in the thermal base load can be compensated for by using a heat accumulator.
The generated electrical energy can be used by the consumer itself, or supplied to the public power system.

Buffer accumulator control
The cogeneration power plant module is started or stopped using a buffer accumulator control. 4 sensors are
evaluated in the buffer accumulator for this purpose. The system displays whether the buffer accumulator is
being filled or drained.
The end of the heating-up time of the genset, additional heat generators (e.g. boiler) are released for activa-
tion. If the gradient evaluation detects that the buffer accumulator is already being filled again, selection of
other generators is prevented.
Heat operation with biogas

During operation of gas engines with biogas, there will be fluctuations in the CH4 content to a greater or
lesser extent, usually as a result of the dosing and composition of the organic material.
Here, it is possible to cover the remaining current requirement or to compensate for fluctuations using an
alternative gas.
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3.1.7.3 Trigeneration – Gas genset
Trigeneration (CCHP) comprises all the options that are also offered in the CHP configuration (→ Page 39). In
addition, cold water is provided in the CCHP configuration by means of adsorption or absorption chillers
(ACs). The requirement for mechanical power is low in ACs, in contrast to the situation with refrigeration
compressors.
The customer's refrigeration requirements is usually greatest in summer when the heat load is low, so ideally
an adsorption or absorption chiller (AC) can be connected to the existing engine coolant/heating water cir-
cuit using a 3-way valve.
Figure 12: CCHP - diagram

1 Supply 4 Cold and heat output to 7 Return
2 Adsorption or absorption load 8 Genset
chiller (AC) 5 Heat accumulator 9 Gas supply
3 Peak load boiler 6 Electrical current for load or
public power system
Similarly to CHP plants, systems with trigeneration can be operated monovalently or bivalently (see dashed
lines).
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The thermal output of the cogeneration power plant has a linear influence on the refrigeration output of the
AC. The graph shows the correlation between the output of the AC and the heating water temperature sup-
plied by the cogeneration power plant.

3.1.7.4 Gas operation – Gas genset
As a rule, gas gensets are operated with one gas type. However, it is also possible to operate the gensets
with two gas types. It is a precondition that the engine must be approved for this operation.
The following gas system configurations are possible:
• Single gas operation
• Two-gas operation with two gas trains and two control valves
• Two-gas operation with two gas trains and one control valve
• Two-gas operation with one gas train and one control valve
Single gas operation
Figure 13: Single gas operation

A gas engine can be operated with natural gas or biogas:
• Purely natural gas gensets are generally regulated according to the electricity or heat requirement, see
(→ Page 18).
• Purely biogas gensets are generally regulated by the available biogas quantity. The electricity generated is
fed into the public power system. The heat generated is used directly on the spot if possible, or fed into a
district heating system.
During operation of gas engines with biogas, there will be fluctuations in the CH4 content to a greater or
lesser extent, usually as a result of the dosing and composition of the organic material. The gas engine
responds to the reduction in the CH4 proportion and simultaneous increase in the CO2 proportion with
constant ignition timing and delayed combustion. The efficiency drops and the exhaust temperature in-
creases.
CH4 control for individual biogas gensets

CH4 control using the MMC can only be employed with individual gensets. In multiple gensets, control is im-
TIM-ID: 0000055294 - 001
plemented using higher-level I&C.

The start requirement and the rated power value are calculated automatically by the CH4 control and speci-
fied for the engine. If this operating mode is active, the current rated value comes from the CH4 control.
Gas tank control for individual biogas gensets

The start requirement and the rated power value are calculated automatically by the gas tank control and
specified for the engine. If this operating mode is active, the current rated value comes from the gas tank
control.
Evaluation is either by way of an analog signal (standard) or digital signals (3 contacts). All parameters must
be found by the customers themselves.

Gas tank control using the MMC can only be employed with individual gensets. In multiple gensets, gas tank
control is implemented using higher-level I&C.
Multi-gas operation
Multi-gas operation using MMC can only be used with individual gensets. In multiple gensets, control is im-
plemented using higher-level I&C.
Especially with biogas gensets, it is possible for the available biogas quantity to be insufficient for generating
the necessary electricity. Here, it is possible to cover the remaining current requirement using an alternative
gas.
Precondition: The engine is approved for this operation!
The following versions of multi-gas systems are possible:
• Two-gas operation with two gas trains and two gas control valves
• Two-gas operation with two gas trains and one gas control valve
• Two-gas operation with one gas train
In a two-gas unit, the biogas train must be allocated to one gas train. This means the gas compressor is auto-
matically requested, for example. Furthermore, it is possible to have the gas type selected externally.
Multi-gas operation control using the MMC can only be employed with individual gensets. In multiple gen-
sets, multi-gas operation control is implemented using higher-level I&C.
Two-gas operation with two gas trains and two gas control valves
Figure 14: Two-gas operation with two gas trains and two gas control valves
Two gas trains are fitted in these gensets.
The changeover to the other gas type only takes place in idle state or during operation linked to the distribu-
tion network:
• When changing over from "local" to "remote", the digital input signal "External selection gas type B" is
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once again given priority.

• If the changeover cannot be performed because of a failed test in phase 1 and 2, the gas exchange is
canceled and the genset switched off. Once a gas exchange has been performed, it can no longer be can-
celed manually.

Two-gas operation with two gas trains and one gas control valve
Figure 15: Two-gas operation with two gas trains and one gas control valve
In these gensets, two gas valves and two gas leak monitors are fitted, but only one regulating valve.
The changeover to the other gas type only takes place in idle state or during operation linked to the distribu-
tion network:
• When changing over from "local" to "remote", the digital input signal "External selection gas type B" is
once again given priority
• If the changeover cannot be performed because of a failed test in phase 1 and 2, the gas exchange is
canceled and the genset switched off. Once a gas exchange has been performed, it can no longer be can-
celed manually.
Two-gas operation with one gas train
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Figure 16: Two-gas operation with one gas train

Only one gas train is fitted in these gensets. This type is usually used for biogas and propane.
For operation with propane, there is an orifice plate installed in the gas train before the gas mixture inlet to
restrict the gas quantity for this gas type. If there is a changeover to biogas, the orifice plate must be re-
moved and the gas train connected to the new gas source. Only then is it permitted for the gas type to be
changed over on this side (only possible locally).

3.1.7.5 Operational limits for gas gensets
The released load stages are based on ISO 8528-5 and apply to defined frequency dips and spikes during
load imposition or load shedding.
With regard to the dynamic properties, the limit values in the following tables apply. Longer stabilization
times may be required.
Performance class G1
Name Specified operational limits (DIN ISO 8528-5)
Static frequency deviation ≤2.5%
Static frequency deviation in relation to speed droop 8 %
Temporary frequency deviation +18% to -25%
Frequency settling time 10 seconds
Static voltage deviation ±5 %
Temporary voltage deviation +35% to -25%
Voltage settling time 10 seconds
Performance class G3
Name Specified operational limits (DIN ISO 8528-5)
Static frequency deviation ≤0.5%
Static frequency deviation in relation to speed droop 3%
Temporary frequency deviation +12% to -15%
Frequency settling time 3 seconds
Static voltage deviation ±1%
Temporary voltage deviation +20% to -15%
Voltage settling time 4 seconds
Apply for the load stage diagrams from MTU Onsite Energy to calculate other classes, classifications acc. to
ISO 8528- 5.
The electrical active powers that can be switched on and off are shown in relation to the current electrical
active power. The stages do not relate to the rated power of the loads, but to the momentary power con-
sumption at the time of the switch-on or switch-off. With inductive loads, the starting power, for example,
must be used for calculation.
Independently of the frequency settling time, a time of at least one minute must be included between load
applications to allow thermal and control settling.
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3.2 Customer Requirements
3.2.1 Emissions
Emissions means the general output of polluting factors into the environment. The following are important
for gensets and their configuration:
• Noise (sound)
Noise is generally defined as disruptive or unwanted sound. Within this handbook, noise is defined as any
sound that is created as a byproduct of diesel engine or system operation.
• Exhaust
Within this handbook, exhaust is defined as gaseous or solid byproducts (soot) of engine operation.
• Waste heat
Within this handbook, heat emission is defined as any radiant heat, without taking account of heat dissipa-
tion by the cooling system.
Measures for reducing sound, exhaust and heat emissions can influence the performance properties of the
genset (e.g. increasing the exhaust back pressure) (→ Page 65).
National and regional regulations on noise and exhaust values in the relevant countries must be complied
with.
Acoustics
In order to configure the acoustic insulation, specific acoustic spectra are recorded and supplied by MTU
Onsite Energy for engine surface noise (including intake noise) and exhaust noise.The following values are
specified:
• Sound pressure level
• Sound power level
The spectra presented for the engine surface noise are logarithmically averaged spectra from a number of
measuring points that depends on the size of the engine. The measuring distance, i.e. the distance from the
microphone to the engine reference surface during the measurement, is 1 m.
The term free-field spectrum means that the level determined in the test stand is reduced arithmetically by
the external noise share and by the share reflected by the test stand walls. This is the only way that such
spectra from different engine manufacturers are comparable.
The spectra are based on measurement with the MTU Onsite Energy standard air filters, i.e. the measured
values already contain the intake noise. This usually corresponds to normal installation conditions of gen-
sets. When other air filters are used, deviation in the entire engine noise spectrum are possible.
Sound pressure level (Lp)

One of the central magnitudes in acoustics is the sound pressure level which is required to describe the
sound volume as a function of the distance. The sound is specified in the form of a sound pressure spectrum.
The sound pressure level (Lp) is defined as a logarithmic dimension for the ratio between the measured
sound pressure (p) and a reference sound pressure (p0).
Lp = 20 x log (p/p0) [dB]
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p = p0 x 10Lp/20 [Pa]
p0 = 2 x 10-5 [Pa]
Sound power level (Lw)

The sound power level is the identifying technical sound magnitude for a source of noise. In contrast to the
sound pressure level, the sound power level is completely independent of the sound field, i.e. from the size
and shape of the room and distance to the source.
The sound power level (Lw) is defined as a logarithmic dimension for the ratio between sound power (W) and
reference sound power (W0).
48 | Customer Requirements | E 2015-08

Lw = 10 x log (W/W0) [dB]
W0 = 1 x 10-12 [W]
W = sound power [W] – a variable independent of the distance and room, which is suitable as a starting point
for all technical sound calculations. It is not measurable directly but can only be determined using certain
measurement procedures.
Conversion of acoustic pressure level into sound power level

Total or individual sound pressure values increase by the measurement surface ratio LS. The measurement
surface ratio is determined from the surface at 1 m distance to the body of the sound source
LW = LP + LS
• L W = sound power level (dB)
• LP = sound pressure level (dB)
• LS = measurement surface ratio (dB)
• LS = 10 x log (S/S0)
S = measurement surface in m2
S0 = reference surface = 1 m2
Undamped exhaust noise

At MTU Onsite Energy , the exhaust noise (without silencer) is measured outside the test stand, i.e. "out-
doors". The room level correction is therefore not required because the free-field spectrum is already record-
ed. The spectrum is logarithmically averaged from the measured values a two points at a distance of 1 m
from the pipe outer edge at an angle of 90° in relation to the pipe center axis.
Some engine manufacturers issue A-weighted spectra or determine the engine surface noise with intake
noise (intake noise from the outside). When comparing with MTU, take note of comparable site conditions.
Exhaust values
The gensets from MTU Onsite Energy are qualified according to different country-specific exhaust gas stand-
ards, among others:
• TA-Luft (TA-air) (Europe, in particular, Germany and Austria)
• EURO standard (Europe)
• EPA TIERs (USA)
• NEA ORDE (Singapore)
• ARAI (India)
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E 2015-08 | Customer Requirements | 49

3.2.2 Requirements Related to Electric Load
3.2.2.1 Load properties and special features

The type of loads and their imposition have varying significance in the different operating modes of the en-
gine-generator sets.
The loads and their properties are highly important in gensets that are operated in isolated operation or in
standby power operation because the power of the gensets is determined by the imposed loads.
In gensets in grid parallel operation, the load changes are divided between many supplying power plants,
which means there is only a slight change for the individual genset. In grid parallel operation, the load is not
important and the current is supplied with a constant cos phi.
In the course of application engineering for isolated operation or standby power operation, it is necessary to
analyze the connected load in advance so as to determine the effects on the genset.
Electrical loads have different electrical characteristics that must be defined during an analysis:
• Linear loads
Loads that absorb sinusoidal current:
– Ohmic loads
– Inductive loads
– Capacitive loads
• Non-linear loads
Loads that absorb a non-sinusoidal current when a sinusoidal voltage is applied.
Linear loads
Ohmic loads
Ohmic loads (effective power loads) convert the complete total input power into heat and/or brightness. The
specified output power (watt) is always also the input power that is output from the generator.
The ohmic loads include, e.g.:
• Incandescent lamps
• Heaters
• Hotplates
Ohmic loads are only considered with the specified rated power (effective power). The active power under
load by ohmic loads is calculated by:
P=uxi
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50 | Requirements Related to Electric Load | E 2015-08

Figure 17: Profile of voltage, current and power with ohmic loads
p Power i Current U Voltage
Inductive loads
Inductive loads are devices driven by an electric motor, e.g.
• Hammer drill
• Circular saw
• Compressor
• Coolant pump
In an inductive load, the energy supplied by the producer is used for establishing a magnetic field. In this
case, the current, voltage and power no longer match up. There is a phase shift in the current. The current
precedes the voltage (see figure). The phase shift is normally specified with phi. In this case, the active pow-
er is calculated by:
P = u x i x cos phi
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E 2015-08 | Requirements Related to Electric Load | 51

Figure 18: Profile of voltage, current and power with inductive (capacitive) loads
p Power i Current U Voltage
A special case applies when the voltage and current curves are "in phase" (phi = 90°). This is referred to as
reactive power because no net energy is generated or consumed in the system, which is why P = 0.
Motors require more power when starting; this can be 3 to 6 times the rated power depending on the type of
device and quality of the motor. The starting power is normally specified as the fuel stop power or Locked
Rotor Amps (LRA). Occasionally a genset will supply double the specified power for a short period. As a re-
sult, the genset must be sufficiently large to cope with the starting currents that occur. To calculate a genset,
the starting power of the inductive loads should be calculated taking account of the simultaneity factor.
The transient voltage drop of the generator during start-up must also be taken into consideration. As the
generator is not able to produce full power immediately when starting, it may not be able to supply the nec-
essary power for all starting inductive loads. In this case, several gensets may have to be connected in paral-
lel, or frequency converters connected in between.
The illustration (→ Figure 19) shows a diagram of a voltage drop (tU, in) after generator start (1). Hereby, tU, in is
the time the generator requires to return to within the performance parameters (Δ U). In the case of a stop or
decrease in performance, a voltage drop also results. As the generator is not able to end the power output
immediately, for a short time (tU, de) too much power is produced that has to be compensated (buffer).
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Figure 19: Voltage drop (from ISO 8528-5:2013)
t Time 1 Power increase (start)
U Voltage 2 Power decrease (stop)
The active power consumption during starting of asynchronous motor is shown here by way of example:
• Direct activation of electric motors to approx. 100 kW: Pin = 2.5 x Pn (e-mot)
• Direct activation of electric motors from 100 kW onwards: Pin = 2.3 x Pn (e-mot)
• Starting aid by star-delta switch-on: Pin = 1.5 x Pn (e-mot)
• Starting aid via thyristor controller or starting transformer: Pin = 1 to 1.5 x Pn (e-mot)
Capacitive loads
In a capacitive load, the energy supplied by the producer is used for establishing an electric field, e.g.:
• Flashing light
• Professional discharge lamps
• Electric power systems with non-regulated compensation devices
In a capacitive load, the energy supplied by the producer is used for establishing an electric field. In this
case, the current, voltage and power no longer match up. There is a phase shift in the current. The voltage is
ahead of the current. The phase shift is normally specified with phi. In this case, the active power is calculat-
ed by:
P = u x i x cos phi
The energy transported per period for establishing and degrading the field is reactive power. Capacitive loads
are the most critical loads because of their charging function.
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Synchronous generators can only absorb reactive power from the power system to a limited extent. Usually
approx. 30% of the apparent power can be absorbed (corresponding to cosφ = 0.95 cap.). Failure to comply
with this limit leads to damage and failure of the genset.
Non-linear loads
Non-linear loads are loads that absorb a non-sinusoidal current when a sinusoidal voltage is applied. For ex-
ample, power supply units for computer monitors or televisions first convert the sinusoidal mains voltage
(e.g. of 230/ 400 V, 50 Hz) into a direct voltage and then, artificially, into a sinusoidal voltage with a consid-
erably higher frequency.

Non-linear loads are:
• Frequency converters for controlling electric motors
• Ballasts of fluorescent lamps (EVG)
• Entertainment electronics devices
• Computer power supply units and monitors
Non-linear loads impose a load on the generator and its voltage due to their harmonics. Harmonics result
through deviations from the basic sinusoidal oscillation (50 Hz or 60 Hz). These harmonics are represented
as the 3rd, 5th, 7th, etc. harmonics. The magnitude or influence of each harmonic is specified as a percent-
age of the underlying fluctuation, and is also referred to as the harmonic distortion.
Attention must also be given to the commutation in the rectifier power circuits. Here, so-called commutation
notches can occur through converters with B6-rectifier circuits and line thyristor bridges. These commutation
notches can be specifically restricted by free-wheeling diodes and/or asymmetrical control processes.
As a result, the following points must be considered when configuring the genset:
• Configuration with regard to heating:
– The max. permitted power output from the generators must be reduced depending on the converter
load.
– The following point of reference applies:
Non-controlled rectifier: Reduction to approx. 95%
Controlled rectifiers: Reduction to approx. 85%
• Configuration with regard to harmonic distortion and commutation notch:
– According to VDE 0160, the voltage harmonic distortion Ku can be max. 10% and the commutation
notch max. 20%.
– Overdimensioning of the generator with regard to harmonic distortion and commutation notch acc. to
VDE 0160
Harmonic distortion: 2 to 5-fold
Commutation notch: 5 to 8-fold
A 1.5 to 3-fold overdimensioning is common practice for price reasons. If this dimensioning is insufficient,
it can be improved if necessary through additional measures (filters; choke coils) (applies to 6-pulse con-
verters).
With 12-pulse converters, approx. half of the above-mentioned value must be calculated, however not less
than 1.2-fold.
A check by MTU Onsite Energy of these calculations is necessary.
Regenerative loads
With regenerative loads such as cranes or lifts, the engine of the consumer can act as a generator with brake
power. If it is not designed as an ohmic load, the brake power will be supplied. The capability of the engine-
generator set to absorb regenerated power is very limited and, depending on the design, is between 10 and
15% of the rated power. Applications in which regeneration is possible or desired, must be checked for suita-
bility. In such cases, we strongly recommend that you consult with the genset development department at
MTU Onsite Energy
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3.2.2.2 Current load types
The specified loads combine to form the current load that has to be supplied by the genset(s).
All devices are used at different times, for different periods and with different intensity, as a result of which
there is a complex interplay between many factors that combine to produce a load profile. Normally, this
profile results in three different current load types:
• Base load
• Medium load
• Peak load
Due to different, very special requirements, gensets and cogeneration power plants usually cover only one
load type.
Base load
This current load type is required around the clock. Gensets or cogeneration power plants designed for this
load type and therefore run in continuous operation at full load.
In case of a failure or maintenance work, however, reserve power must be provided.
MTU Onsite Energy gensets (diesel and gas) and cogeneration power plants (gas) are ideal for this load type.
Medium load
This current load type depends on the time of day, or season, and is thus calculable. Depending on the size
and power requirements, MTU Onsite Energy gensets and cogeneration power plants can be operated such
that they cover both base loads as well as medium loads.
In case of a failure or maintenance work, however, reserve power must be provided.
MTU Onsite Energy gensets (diesel and gas) are ideal for this load type. When a cogeneration power plant
(gas) is used, it must have a current-controlled design; an examination is therefore required as to how the
thermal energy is saved and discharged (buffer accumulator).
Peak load
This current load type is required for unexpected incidents. As peak loads can have high rates of change (up
to 20% rated load / min.), the gensets of cogeneration power plants must be configured accordingly. Simul-
taneity factor, load imposition and switchover time play an important role.
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3.2.2.3 Load management
Load management by the genset control divides up the overall load between the available gensets. MTU On-
site Energy recommends that an operational data recorder should be used for analyzing unscheduled engine
shutdowns at the client's premises.
If gas gensets with the same number of cylinders and same configuration are used (isolated parallel opera-
tion), select the following procedure:
Total load stage = load stage of gas genset for isolated operation x factor 0.9 x number of gas gensets
Basically, isolated parallel operation of gensets with the same number of cylinders is recommended. If this is
not possible, the preferred alternative is a combination of neighboring cylinder numbers (8V + 12V, 12V
+ 16V, 16V + 20V). In this case, select the following procedure:
Total load stage = load stage of gas genset with smallest number of cylinders x factor 0.9 x number of gas
gensets
Some gas engines - independently of the charging efficiency - are not able to take over a 100% load cut-in in
one stage. The reasons for this, among other things, are related to the mean effective plunger pressure and
the fuel introduction. The possible load cut-in can be obtained from the technical documentation.
As opposed to liquid fuels that can react very quickly to changes in the injection pump due to their incom-
pressibility, the compressibility of gaseous fuels results in a slower control action.
More detailed information and the load stage diagrams are available from MTU Onsite Energy.
The advantage of gas engine, in particular, is less problematic exhaust gas cleaning and the low cost of water
protection.
for larger power units in the MW range, problems can arise in the case of a mains failure if the interruption
time has to be less than 15 seconds. In the lower power range (< 1 MW), in the meantime, this requirement
can be met.
Load stages
The released load stages are based on the ISO 8528-5 standard and apply to defined frequency dips and
spikes during load imposition or load shedding. Load switching curves depend on the configured genset.
Special genset curves can be requested from MTU Onsite Energy.
ISO 8528-5 defines terminology and design criteria for electricity generating gensets that are a combination
of reciprocating internal combustion engines and alternating current generating sets. Operational limits are
defined with regard to the static and dynamic voltage and frequency behavior, e.g.:
• Maximum speed increase on load shedding and maximum speed dip on load imposition
• Maximum voltage increase on load shedding and maximum voltage dip on load imposition
• Stabilization times between the load stages
ISO 8528-5 is divided into four performance classes G1 to G4. The following three performance classes are
used for gas gensets:
• G1 – performance class with the lowest requirements
• G2 – performance classes with medium requirements
• G3 – performance class with the highest requirements
• G4 – performance with definable requirements between customer and supplier. Note: We recommend
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that details be clarified with MTU Onsite Energy. In case of doubt, the sale should include G4 because the
requirement have to coordinated specially with the customer.
Load profile
A load profile must be prepared for the feasibility study. Over a period of at least 24 hours, the output, power
factor, voltage and frequency at the mains transfer point are recorded. If the loads vary on different week-
days or in different seasons, the recordings must be extended to these areas.
Standard ISO 8528-1 defines the maximum permissible load for gensets in standby and continuous opera-
tion. The genset must therefore be configured in accordance (→ Page 34) with the desired type of service.

3.2.2.4 Power calculation
The design of the genset is determined by the following factors:
• Actual power output (engine) (→ Page 28)
• Apparent power (generator) (→ Page 28)
• Objective power requirement (→ Page 32)
• Load stages (→ Page 32)
Normally, application engineering is based on the variable continuous power. Depending on the application
group, it is necessary to take account of the 120% overload capability for technical control purposes (see DIN
3046).
Rated power
The rated power P is calculated from the total of all loads (Vtot) and the simultaneity factor (g) (→ Page 32).
The properties of the loads must be considered in particular here (→ Page 50).
P = Vtot x g
Total genset power

The total power S to be developed by the genset results from the r.m.s. values of electrical current intensity I
and electrical voltage U.
The total power should be sufficient to supply the loads on the power system as well as the loads on the
genset:
S = S1 + S2
S = required minimum generator power (kVA)
S1 = required load power (kVA)
S2 = total of the loads required for the genset auxiliary drives (kVA) such as cooler fan, fuel pump, etc.
Effective power output of generator

The effective power output of generator (P) is the electrical power that is available to be converted into other
powers. It is necessary to differentiate it from the reactive power which can not be used for this conversion.
The apparent power (S) corresponds to the total power and results from the r.m.s. values of electrical cur-
rent intensity I and electrical voltage U (→ Page 28).
P = S x cosφ
P = the minimum active power output from the generator (kW)
S = the minimum apparent power output from the generator in (kVA)
cos φ = power factor
Generator efficiency
The generator efficiency ɳ is a measure of the efficiency of the energy conversions and energy transfers. It is
a dimensionless parameter and describes the ratio between the effective power Pout (specified in electrical
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energy: kWe) and the supplied power Pin (specified in mechanical energy: kWm) (→ Page 28).
The generator efficiency (ɳ) is calculated using the current/speed characteristic curve and the input power/
speed characteristic curve of the generator; this must be obtained from the generator manufacturer.
ɳ = Pout (kWe) / Pin (kWm)
Pin = Pout / ɳ (kW)

Engine minimum power
The minimum power of the diesel engine Pengine must correspond to the power Pin to be supplied of the gener-
ator.
Pin (kWm) = Pengine (kW)
or
Pengine (kWm) = S (kVA) * cosφ / ɳ (kW)
The engine type in question must be found with reference to the applicable MTU delivery range in question,
under the corresponding performance group.
If no suitable engine type is available, select the type with the next higher power rating.
It is adequate for the same method to be used for the generator, according to the generator manufacturer's
delivery range.
Rated genset current

In the event that the standby switchgear is equipped with a power section, the minimum current intensity is
calculated from the actually defined genset power S as follows:
J (A) = S (kVA) / U (kV) * 1.73
Transient voltage drop

Load changes cause a voltage drop at the generator. This voltage drop is determined by the generator prop-
erties.
∆u = √3 x I x (Rg x cosφ + Xd' x sinφ)
whereby:
• ∆u: Transient voltage drop [p.u.]
• Rg: Generator effective resistance [Ω]
• Xd: Transient normalized reactance [Ω]
• φ: Load angle of the switch-on power
Example: An engine with a shaft output of 140 kW in star-delta starting must observe a transient voltage
drop of 10%. The necessary generator output in this case is approx. 750 kVA.
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3.2.3 Requirements Related to Thermal Load
3.2.3.1 Load properties and special features

Engine-generator sets operated as cogeneration power plants consist of an engine/generator unit with asso-
ciated heat exchangers for using the thermal energy in the mixture, coolant, lube oil and exhaust gas.
Cogeneration systems (CHP plants) generate electricity and heat on a decentralized basis at the location of
demand. They offer the greatest possible efficiency in energy conversion with minimum environmental pollu-
tion.
The electrical efficiencies of cogeneration power plants range between approx. 30% and in excess of 40%
depending on the type of engine and output; the thermal efficiencies are in a range between about 50% and
60%.
Losses of approx. 10% occur during energy conversion. These are composed of generator, radiation and heat
exchanger losses, as well as the unused heat from the exhaust gas.
Objects receiving supply:
• Housing estates
Domestic hot water requirements and similar use in housing estates produce the higher peak load propor-
tion. The heat demand for heaters form the base load proportion. New residential units are characterized
by good thermal insulation, as a result of which the base load (heating) proportion is reduced.
• Hospitals
In hospitals, a steady thermal base load and high electricity consumption provide ideal conditions for us-
ing cogeneration power plants. Furthermore, they can also be used for emergency power supply.
• Industrial companies
The heat required by industry fluctuates greatly over the course of production (e.g. breweries), as a result
of which consumption profiles must be drawn up during the planning phase in order to achieve a compre-
hensive and economical energy concept.
Thermal load properties

Heat created during the combustion process has to be dissipated. It can either be discharged via suitable
coolers to the atmosphere or provided to the customer via heat exchangers. The load of the heat consumer
and lost heat of the cogeneration power plant must be tuned to one another. The following section explains
the most important parameters for determination of the load properties.
Maximum heating load (daily profile)

The heating load is calculated by adding together the ventilation and transmission heat losses, as well as
process water consumption. Ideally, measurement data is sampled on several representative days (particu-
larly cold, overcast, etc.). The maximum established heat load is then used as the basis for calculation. This
measuring technique has some disadvantages, for example, because it fails to consider heat sources in the
room and the effect of sunlight.
As a result, it is necessary to obtain other data in order to calculate the load and set the dimensions of a
system – this is best done directly by the system operator.
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E 2015-08 | Requirements Related to Thermal Load | 59

Figure 20: Annual heat requirement (X-axis: months; Y-axis: Thermal output in %)
1 Thermal base load
Annual load duration curve

The annual load duration curve shows the thermal output required during the course of a year. As a result,
the annual load duration curve shows how the heat load is distributed over the year.
This data can be obtained from the system operator. During planning, this display helps in estimating the
total requirements and the load arising in the course of a year.
Ordered annual load duration curve

In the ordered annual load duration curve, the required thermal output is shown over the respective utiliza-
tion time (in hours). The annual load duration curve thus shows you for how many hours a specific output is
required. A flat curve shows you therefore that the corresponding output is required for a particularly long
period.
During the planning phase, the cogeneration power plant is usually dimensioned according to the output
most frequently required. This allows very long runtimes with a load as constant as possible and thus en-
sures maximum efficiency. Peak outputs are usually covered by additional purchase or a boiler (peak boiler).
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60 | Requirements Related to Thermal Load | E 2015-08

Figure 21: Ordered annual load duration curve. X-axis: Operating hours; Y-axis: Thermal output in %
Load properties, cooling

A further property is the seasonal fluctuation of heat demand. In summer it is relatively low, which is why full
utilization of the cogeneration power plant is often not possible at this time. To feed the current into the
power grid, for the above-mentioned reasons heat has to saved using a complex procedure or is dissipated
unused. To avoid this, MTU Onsite Energy offers a combined cooling, heat and power solution (trigeneration).
In summer an absorption chiller is used to generate cooling energy from thermal energy for air conditioners
and similar equipment. Naturally, the simultaneously generated current can be fed additionally to the power
grid.
Note that the calculation of the power properties is more complex than for the heat power properties. This
reason for this is the delayed effect of the cooling capacity, which always takes place via the room air. This
thermodynamic-related delay must therefore be included in the calculation.
The following parameters are important for determination of the power properties and thus configuration of
the plant.
Maximum building cooling load (in the course of a day)

To determine the cooling load of a room or building, measurements are carried out every hours in the
room(s) on several representative days (high outside temperatures, solar radiation on windows etc.). The re-
sults are added up every hour, i.e. all measured values at 12h on the measurement days are added and then
all measured values at 13h, etc. The maximum of all these totals is the maximum building cooling load.
Annual load duration curve

The annual load duration curve shows the room or building temperature during the course of a year. In con-
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junction with the measured values from the cooling load calculation, the temperature can be used to deter-
mine the cooling capacity required in the course of the year.
Ordered annual load duration curve

In the ordered annual load duration curve shows the room or building temperature over the respective utiliza-
tion time (in hours). The annual load duration curve thus shows you for how many hours a specific tempera-
ture is required. A flat curve shows you therefore that the corresponding temperature is required for a partic-
ularly long period.

3.2.3.2 Power calculation
Heat
Normally, application engineering of cogeneration power plants or gensets with a thermal module is based
on the continuous power. Depending on the application group, it is necessary to take account of the 10%
overload capability for technical control purposes.
Heat recovery
The degree to which the engine and exhaust heat is recovered in the heat exchangers depends on the flow
rate Q, the thermal capacity of the heat exchanger medium (c), the thermal output of the cogeneration power
plant P and the temperature difference in the supply and return Δ T.
P=Q*ΔT*c
Heat load
The heat load HL is calculated from the ventilation losses V (opened windows and doors) and the transmis-
sion losses T (heat absorption capacity of the walls, ceilings). Regular (hourly) measurements must be taken
on several days for an objective calculation of the heat load of a room/building.
The calculation formula is: ΦHL = ΦV + ΦT
Cold
During application engineering for cogeneration power plants with trigeneration (CCHP), not only must the
power calculation for heat be performed, but also the cooling load must be calculated. Depending on require-
ments, the heat load and refrigeration load are serviced alternately or simultaneously. This must be taken
into account accordingly when setting the dimensions.
It should be noted that calculating the power properties is more complex than with the power properties for
heat. This has to do with the delayed effect of the cooling capacity, which is always carried out using the
room air. The thermodynamically related delay must be included in the calculations.
Cooling applications
An important basis for calculating the output of a refrigeration system is the heat ratio ζ, the quotient of the
cooling power at the evaporator Q0 and the heating power at the ejector QA.
ζ = Q0 / QA
Cooling load
To find the temperature profile of a room or building, measurements are taken in the room/building every
hour on several representative days (high outdoor temperatures, sunshine through windows, etc.). The re-
sults are added together every hour, i.e. all measured values taken at noon on the measuring days are added
together, then all measured values taken at 1 PM, etc. The maximum of all these totals specifies the maxi-
mum building cooling load. This value provides a point of reference for the room/building temperature that is
to be compensated for.
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In addition, all indoor and outdoor heat sources must be calculated. The cooling load KL is the sum total of
all internal and external heat sources.
Incorrect or inaccurate rating of the cooling load can lead to a system being selected with excessive or insuf-
ficient capacity, thus leading to high follow-on costs.
The calculation formula is: QKL = QM + QB + QN + QG + QR + QW + QF
62 | Requirements Related to Thermal Load | E 2015-08

where:
• QM = Heat output from the human being
• QB = Heat output from the lighting
• QN = Heat output from equipment
• QG = Heat absorption during substance flow
• QR = Transmission from neighboring rooms
• QW = Transmission through walls, roofs
• QW = Transmission through windows
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3.2.4 Fuel Requirements
3.2.4.1 Gas – Requirements

Natural gas
The quality of the fuel is very important for satisfactory engine performance, long engine service life and ac-
ceptable exhaust emission levels. The engines can be operated with different types of gas. The fuels used
must comply with the specifications in "Fluids and Lubricants Specifications: 400 series" (DK-BS-0001) or
"Fluids and Lubricants Specifications: 4000 series" (DK-BS-0002).
Gas engines must be operated exclusively with gases which have been specifically approved for the type of
engine in use. The gas composition must be analyzed every six months so as to detect changes in quality and
allow suitable measures to be taken.
At the latest prior to commissioning, contact the responsible gas supplier to make sure that the specified
methane number and calorific value range are complied with. At the same time, ask whether butane or pro-
pane are admixed from time to time.
Biogas and sewage gas

In contrast to the situation with natural gas, it is not possible to avoid fluctuations in gas quality with biogas
and sewage gas. MTU gensets are designed to deliver maximum performance at minimum operating costs,
even when operating with biogas and sewage gas. Nevertheless, certain limit values must be complied with
so as to avoid malfunctions and damage. The fuels used must comply with the specifications in "Fluids and
Lubricants Specifications: 400 series" (DK-BS-0001) or "Fluids and Lubricants Specifications: 4000 series"
(DK-BS-0002).
Due to potential fluctuations in the sulfur content in practice, MTU is unable to offer any guarantees regard-
ing the cleaning intervals.
The consumption and emissions values stated in the engine's data sheet only apply to the specified refer-
ence gas composition for biogas. The CO2/CH4 proportions by volume are important in this respect.
Gas engines must be operated exclusively with gases which have been specifically approved for the type of
engine in use. The gas composition must be analyzed regularly.
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64 | Fuel Requirements | E 2015-08

3.2.5 Power Rating
3.2.5.1 Influencing factors on power

The power of the genset engine was measured under the standard conditions defined in ISO 3046-1. Condi-
tions at the installation site deviating from this will influence the engine or generator power, and thus the
genset also. If all necessary boundary conditions are known, it is possible to calculate the maximum achieva-
ble engine power.
The following ambient conditions at the installation site will influence the engine or generator power, and
thus the genset also:
Site conditions
• Site altitude
The site altitude has a direct influence on the air pressure, and thus on the density of the intake air. This in
turn has direct effects on the achievable engine power.
Specification of the site altitude in m above sea level or as barometric pressure in kPa.
• Absolute air humidity
With supercharged engines, at high air humidity levels (tropical conditions) there is a danger that water
condenses on the cooling fins of the mixture cooler. It is necessary to set the coolant temperature accord-
ingly as a reliable means of preventing this. It is therefore absolutely necessary to know the absolute pro-
portion of water of the intake air.
Specification g water / kg moist air or dew point temperature in °C.
• Air temperature
The temperature of the outside air has a direct influence on configuration of the compartment ventilation
and horizontal-core radiator. This means that there is an indirect influence on the coolant temperatures
and the achievable engine power.
Specification of the minimum/maximum ambient air temperature in °C.
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The air temperature has a direct or indirect influence on the following factors that can be influenced by con-
trolling the air temperature:
Factors that can be controlled by air temperature
• Intake air temperature
The intake air temperature has a direct influence on the density of the intake air, and thus on the achieva-
ble engine power.
Specification of the minimum/maximum intake air temperature (engine room) in °C.
• Mixture coolant temperature
The mixture coolant temperature has a direct influence on the mixture temperature, and thus the density
and therefore has a direct influence on the achievable engine power.In combination with the methane
number, the mixture temperature has an indirect influence on the achievable engine power via the knock-
ing resistance. The mixture coolant temperature depends on the type of cooling used (horizontal-core ra-
diator, cooling tower water, cold water, etc.).
Specification of the minimum/maximum mixture coolant temperature in °C or the type of cooling.
• Engine coolant temperature
If mixture cooling is integrated in the engine coolant circuit, an indirect influence on the mixture tempera-
ture and thus the density is possible, which can influence the achievable engine power. In combination
with the methane number, the engine coolant temperature also has an indirect influence on the achieva-
ble engine power via the knocking resistance. The engine coolant temperature also influences the thermal
load of the engine, which is why maximum inlet and outlet temperatures are defined. Through the integra-
tion of the oil cooler in the engine coolant circuit, the oil temperature is directly influenced by the engine
coolant temperature. Maximum temperatures are also defined in this case. The engine coolant tempera-
ture depends on the type of cooling used (heat recovery, horizontal-core radiator, cooling tower water,
cold water, etc.).
Specification of the engine coolant temperature (inlet and outlet) in °C or the cooling method.
• Heating water temperature
If mixture cooling is integrated in the heating water circuit, an indirect influence on the mixture tempera-
ture and thus the density is possible, which can influence the achievable engine power. In combination
with the methane number, the heating water temperature can also have an indirect influence on the ach-
ievable engine power via the knocking resistance. With heat recovery, the heating water temperature has
a direct influence on the engine coolant temperature, which is why maximum temperatures have also
been defined for this.
Specification of heating water temperature (inlet and outlet) in °C.
• Generator cooling air temperature
The load current through the generator winding creates heat in the generator housing. The better the cool-
ing, the higher the permitted load current.
Specification of the minimum/maximum cooling air temperature in °C.
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66 | Power Rating | E 2015-08

The following factors influence the power of the engine or generator, and thus of the genset, and must be
taken into account in the power rating of the genset:
Factors that can be controlled in the system
• Intake depression
Excessively low pressure at the air inlet has a direct influence on the efficiency of the turbocharger, and
thus on the achievable engine power.
Specification of the minimum/maximum negative pressure in mbar.
• Exhaust back pressure
As a result of necessary built-in components such as SCR and /or oxidation catalysts, silencers, exhaust
heat exchangers, exhaust pipe and flue, a significant exhaust back pressure can build up. This has a direct
influence on the efficiency of the turbocharger, and thus on the achievable engine power. An increased
exhaust back pressure also has a negative effect on the axial bearings of the turbocharger because of
increased loading, as a result of which the maximum permitted values are not allowed to be exceeded.
Specification of the minimum/maximum exhaust back pressure in mbar.
• How water quality
The purity of the heating water not only has an influence on the heating capacity and thus the efficiency of
the heat recovery. Ideally, cogeneration power plants are configured such that the heating water is direct-
ed first to the plate-core heat exchanger and then to the exhaust gas heat exchanger. Contaminated heat-
ing water can lead to corrosion in the long term, particularly at the exhaust gas heat exchanger. The heat-
ing water quality must therefore be analyzed during configuration.
• Combustion gas pressure
For safe operation of the engine, it is necessary to provide the incoming gas at the supply point with a
pressure (static and dynamic) that is within the configuration limits.
Specification of the minimum / maximum gas pressure at the interface in bar.
• Fuel gas quality
The combustion gas quality, especially the methane number, has a direct influence on the achievable en-
gine power.
Specification of a detailed gas analysis for all elements of the gas including trace elements.
The standard ambient conditions are listed in the TEN data (Technical Evaluation Network in the MTU-Busi-
ness Portal).
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3.2.5.2 Engine-generator set – Power
Definition of the genset power
An engine-generator set consists of an engine and a generator that form a system. The engine and generator
have their special properties and characteristics, and these properties have an influence on the system.
The individual properties must be considered individually and jointly when selecting an engine-generator set.
HP spec rating program (only for diesel applications)

After the ambient conditions and basic requirements have been entered, the MTU-internal program suggests
the ideal genset. The program calculates the effects of a load imposition on the genset. The calculation is
currently limited to gensets in the 4000 and 2000 series with low-voltage generators 400 V.
Input of ambient conditions:
• Site altitude
• Country selection
Input of basic requirements of the genset:
• Frequency
• Product type
• Voltage
• Fuel type
• Application group
• Detailed input of load stages and loads
The power reduction of the gensets as a function of ambient temperature, site altitude, intake depression
and exhaust back pressure is specified.
Specification of the output that a certain genset can achieve under the given general conditions.
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3.2.5.3 Power ranges – Gas gensets from MTU Onsite Energy
The following table shows the power ranges for gas gensets from MTU Onsite Energy.For more detailed infor-
mation and technical data about the individual gensets, refer to www.mtuonsiteenergy.com.
Gas genset Power at 50 Hz Power at 60 Hz
series
series
Standby power with natural gas or propane - 30 to 400 kWe
Prime power with natural gas - 130 to 355 kWe
Dimensioning acc. to heat load or cooling load

To find out which loads the cogeneration power plant needs to serve in order to operate both efficiently and
economically, it is necessary to calculate the daily and annual requirement for heating and cooling capacity.
An example of the heat supply with two gensets is shown below. The cold supply is calculated similarly.
Calculation
Calculation acc. to the annual requirement is shown below, taking the example of a system for supplying
heat to a housing estate. The line shown may thus vary for other loads (swimming pool, hospital, industry).
The figure (→ Figure 22) shows the ordered annual load duration curve. The bars show the cogeneration pow-
er plants used and their power. The operating hours can be read off as follows:
• Cogeneration power plant 1: approx. 8000 h (continuous power)
• Cogeneration power plant 2: approx. 6000 h
This means the cogeneration power plants cover the entire base load and additionally 30% of the peak load.
The remainder of the peak load can be covered by a peak load boiler, or must be bought in. In statistical
terms, this results in a full runtime of at least 80% for both cogeneration power plants. On average, cogenera-
tion power plants are economical if they operate for 4000 - 5000 h or more under full load. Due to seasonal
fluctuations in the heat demand, it may be worth considering the economic aspects of heat buffer storage
tanks or adsorption chillers (trigeneration) so as to extend the operating duration and make it possible to
generate and monetarize peak load electricity.
The following rules of thumb must be observed:
• Use several gensets (> 2) to avoid supply outages due to failures or maintenance.
• Select sufficiently large boilers to compensate for peak load (70%).
• Investigate the profitability of an additional electricity supply feed
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Figure 22: Ordered annual load duration curve (using the example of a hospital)
1 Peak load boiler
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3.3 Planning Criteria
3.3.1 Engine-generator set – Overview
The following section presents the engine-generator sets for gas operation and their components offered by
MTU Onsite Energy by way of example. The engine-generator sets shown can be configured based on the
system business units of MTU Onsite Energy (→ Page 10).
Irrespective of what the requirement is, e.g. continuous, standby or prime power supply, straightforward
electrical power generation, cogeneration (combined heat and power, CHP) or trigeneration (combined cool-
ing, heat and power, CCHP), in all cases the gas gensets from MTU Onsite Energy represent an effective,
reliable solution that is configured precisely according to customers' requirements.
MTU Onsite Energy gas gensets are classified in three function categories:
Gensets purely for electricity generation (GB)

These genset have the following main assemblies:
• Engine (including gas train)
• Generator
• MMC (for control, regulation, diagnostics)
In the combustion engine, the energy contained in the fuel is converted into mechanical work and heat. The
generator, which converts the mechanical work into electrical energy, is flanged-mounted on the engine via a
resilient coupling. The connecting bell is provided with a service port that permits the replacement of the
flexible coupling element without displacing the engine or generator. The engine and generator are connect-
ed via resilient, vibration-damped elements with the baseframe. All control and monitoring systems, including
communication options to and from external points are implemented by the hardware and software inside
the switch cabinet.
Gensets with heat supply from cogeneration from engine coolant circuit (GR)
• Generator
ed via resilient, vibration-damped elements with the baseframe. The engine coolant dissipates the engine
heat and the heat quantity drawn from the mixture. This dissipated heat is directed to the heating water sys-
tem via a plate-core heat exchanger. All control and monitoring systems, including communication options to
and from external points are implemented by the hardware and software inside the switch cabinet.
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Gensets with supply from cogeneration from engine and exhaust gas cooling circuit
(GC)
• Generator
• Exhaust silencer
• MIP (MTU Interface Panel) for engine control, regulation, diagnostics
ed via resilient, vibration-damped elements with the baseframe. The engine coolant dissipates the engine
heat, the mixture heat of the 1st stage and the heat quantity drawn from the exhaust gas by means of the
exhaust heat exchanger. This dissipated heat is directed to the heating water system via a plate-core heat
exchanger. This plate-core heat exchanger, the exhaust gas unit with lambda sensor and catalytic converter
(optional) are installed with complete pipework in the baseframe. The mixture heat from the 2nd stage is
dissipated via a cooler. The plate-core heat exchanger represents the interface between module and custom-
er-provided heating system. All control and monitoring systems, including communication options to and
from external points are implemented by the hardware and software inside the switch cabinet.
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Example of structure of the 400 series
Figure 23: Series 400 Power Module

1 Switch cabinet (MMC) 8 Separate lube oil cooler 15 Pressure switch (coolant
2 Engine Interface Panel (MIP) 9 Draining / filling lube oil pressure min.)
3 Actuator, throttle flap 10 Heating water inlet 16 Draining / filling (coolant)
4 Level display and float 11 Draining / filling heating 17 Diaphragm expansion tank
switch (lube oil) water 18 Diaphragm expansion tank
5 Lambda sensor 12 Draining / filling coolant 19 Mounting
6 Exhaust pipe 13 Pressure gauge (coolant 20 Emergency-stop button
7 Coolant pump pressure)
14 Coolant heat exchanger
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Example of structure of the 4000 series
Figure 24: Genset without heat module with gas train

1 Gas inlet 5 Mixture coolant outlet 9 Coolant inlet
2 Exhaust outlet (stage 2) 10 Coolant outlet
3 MIP - switch cabinet 6 Lube oil drain 11 Mixture coolant inlet (stage
4 Mixture coolant inlet (stage 7 Lube oil spraying 1)
2) 8 Lube oil supply 12 Mixture coolant outlet
(stage 1)
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3.3.2 One-line diagram
A one-line diagram is a form of circuit diagram. It is a significant feature that the electrical conductors re-
quired in a circuit are not shown individually, but rather schematically by a single connecting line. This dis-
play type with its graphic symbols is defined in DIN EN 60617-6.
The one-line diagram is an important planning aid for providing an overview of the system and the connection
arrangement. Here, the main components of the system and the overall connection diagram are shown. De-
pending on the requirement and the application, the diagram shows the following information:
• Standardized graphic symbols for transformers, circuit breakers, generators or inverters
• Voltage or powerflow specifications
• For power stations, the essential consumers such as pumps
The specifications in this diagram are important during the planning, installation and commissioning phases.
A one-line diagram should be prepared as early as possible during the project planning phase.
Typical one-line diagrams are shown here (→ Page 183), (→ Page 185).
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3.3.3 Dimensioning – Gas genset
Once the genset size and application have been determined, it is advisable to configure individual compo-
nents of the genset or infrastructure to match them. The table below represents a rough guideline of the
existing options. Country-specific specifications or guidelines can not be considered at this point.
Dimensioning the engine

The following parameters must be found or clarified with the customer so that the engine can be dimen-
sioned correctly:
• Continuous power
• Switch-on power
Both parameters can be defined more precisely by specifying the scope of application and the application
group.
Component Parameters (among other things) Notes
Engine Power, consumption, dimensions (→ Page 80)
Dimensioning the generator

The following parameters must be found or clarified with the customer so that the generator can be dimen-
sioned correctly:
• Application group (continuous power, standby power, etc.)
• Load power
• Switch-on power
• Short-circuit power/apparent power
• Reactive power
The output voltage can be calculated using the reactive power. The corresponding characteristic curves can
be found in the technical data of MTU Onsite Energy generators and are used for calculating the rated power.
The rated power may well be higher than the load power.
It should be noted that cos φ = 0.8 must normally be used in the calculation.
Component Parameters (among other things) Notes
Generator Power, winding, insulation (→ Page 81)
Dimensioning other genset components and infrastructure

Dimensioning of the other components is primarily based on the power requirements by the engine and gen-
set, or according to the ambient conditions.
Exhaust system
The exhaust system consists of several components which can be found in the "Configuration" chapter. In
this case, components that are directly connected to the genset are distinguished from the infrastructure
components.
Genset component Requirements Notes
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Exhaust system Exhaust back pressure (→ Page 94)
Infrastructure component Parameters (among other things) Notes

Exhaust system Piping, neutralization, flue (→ Page 127)
Engine cooling system

The engine cooling system must be configured according to the selected MTU Onsite Energy system. This is
dispensed with in systems with an integrated engine cooler.

The engine cooling system consists of several components which can be found in the "Configuration" chap-
ter. In this case, components that are directly connected to the genset are distinguished from the infrastruc-
ture components.
Engine cooling system Air-water/water-water cooling (→ Page 97)

Coolant supply system Horizontal-core radiator, coolant expan- (→ Page 141)
sion tank, lines
Ventilation system
The ventilation system consists of several components which can be found in the "Configuration" chapter. In
this case, components that are directly connected to the genset are distinguished from the infrastructure
components.
Intake air system Differential pressure (→ Page 91)

Ventilation system Ventilation type, diffusers, louvers (→ Page 120)
Installation compartment
This concerns gensets for stationary operation in a building. The installation compartment should at least
meet the requirements acc. to DIN VDE 0100-731 for enclosed electrical operating facilities.
Switchgear must be set up acc. to DIN VDE 0100-729.
Construction regulations must also be considered, depending on the installation site. This applies to gensets
for standby power and safety electrical supply. The regulation on construction of operating compartments for
electrical systems (EltBauVO) applies to:
• Department stores, commercial premises
• Gathering places (without temporary structures)
• Office, administration buildings
• Hospitals, retirement and care homes, nurseries
• Hotels and restaurants
• Enclosed large garages
• Residential buildings
Furthermore, it is necessary to ensure that the genset and the genset compartment are provided with corre-
sponding warning and safety instructions as well as fire fighting equipment (fire extinguishers) and any ap-
propriate protective equipment, in accordance with the applicable accident prevention regulations.
Installation compartment Acoustic insulation, ventilation (→ Page 111)
Dimensioning other components

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All other components on the genset and the infrastructure are described in detail in the "Configuration"
chapter.
Starter system Scope of application (quick start) (→ Page 102)
Control Scope of application, operating mode, (→ Page 108)
number of gensets

Fuel system Fuel quality, reserve quantity (→ Page 87)
Lube oil system Scope of application (quick start, black (→ Page 95)
start)

Fuel supply system Tanks, piping -
Lube oil system Oil tanks, oil pump, oil spraying (→ Page 137)
Wiring Ducts, insulation (→ Page 144)
Starter batteries and battery charger Battery capacity, battery type (→ Page 165)
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3.3.4 P&I diagram
P&I diagram is the name of a pipeline and instrument flow diagram in plant and process engineering. This
shows the required components and the necessary measuring and control engineering with standard sym-
bols.
The components required for operating a system, such as tanks, apparatuses, pumps, compressors, heat
carriers, pipelines, valves, fittings and measuring instruments are shown symbolically. All lines that depict a
pipeline are identified, if necessary, with nominal width, rated pressure, medium, pipe class and an ID num-
ber.
The measuring and control engineering is defined by standardized symbols (ovals). Where and what should
be measured or controlled is specified. Also, these specifications contain an identification number for further
processing.
A P&I diagram contains the following information:
• Type and designation of the apparatuses and/or machines
• Pipelines, valves and fittings with nominal widths, pressure stages, materials
• Drives
• Tasks of the devices for measuring and controlling
Additional information can be specified, e.g. heights of apparatuses, further materials, further designations
(e.g. of valves and fittings).
Following approval of the R&I diagram by the customer (and authorities as well if necessary), the detailed
planning begins.
A typical R&I diagram of an engine-generator set is shown here (→ Page 191).
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3.4 Engine-generator set - components
3.4.1 Engines
The following engines are used for gas gensets from MTU Onsite Energy as standard. Furthermore, engines
from third parties are used particularly in the lower power range. This refers mainly to engines from GM, Ford
and Doosan.
Engines for gas gensets
Series 4000
400 series
For detailed information about engines and components, refer to the functional descriptions of the engines in
the MTU-Business Portal.
The complete TEN documents (Technical Evaluation Network) for the individual engines can be found in the
MTU-Business Portal.
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3.4.2 Generator
3.4.2.1 Generator
The electric generator converts mechanical energy (generated by the engine) into electrical energy, generally
by means of electromagnetic induction. The conversion is based on the Lorentz force that acts on moving
electrical charges within a magnetic field.
Inside the generator, the rotor is rotated against the fixed stator housing. The rotor uses a permanent mag-
net or an electromagnet (field coil or excitation winding) to generate a magnetic unidirectional field. This
magnetic field induces electric voltage (Lorentz force) in the conductors or conductor winding of the stator.
Figure 25: Interior view of generator (example)

1 Voltage regulator 6 Drip guard, optional 12 Connection housing
1 a Voltage regulator 7 SAE flange 13 Exciter stator
2 Capacitor 8 Fan 14 Louver grill (air inlet)
3 Rotor and stator of the per- 9 Ventilation grill (air outlet) 15 Field-circuit rectifier
manent-magnet generator 10 Main housing of the genera- 16 Exciter rotor
4 Lifting eye tor with main stator
5 Main rotor 11 Mount-on holder
Closed-loop control
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The output voltage of the generator is regulated by a voltage regulator (1). The voltage regulator is supplied
with voltage by a permanent-magnet generator (3).
Cooling
Generators have forced-air cooling. Air passes through the louver grill (14) into the bottom part of the tap
box, flows past the stator and rotor winding and emerges through grill openings (9) as hot air at the adapter
ring. The fan (8) is cast from an aluminum alloy and driven by the main rotor (5); it ensures an even air flow
rate to maximize the generator cooling.
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Connection housing
The illustration shows an example of the connection housing of a generator (12).
Figure 26: Generator connection housing

1 Digital voltage regulator 5 Exciter stator 9 Diode with forward polarity
2 Fuses 6 Exciter rotor 10 Overvoltage protection
3 Busbar 7 Current transformer for 11 Diode with backward polari-
4 Insulator measuring ty
8 Field-circuit rectifier
Diodes (9 and 11) perform the function of an "electrical non-return valve". They conduct in one direction only
and convert alternating current (AC) into direct current (DC). Three diodes with forward polarity (9) and three
diodes with backward polarity (11) are used. The overvoltage protection (10) has polarity-reversal protection.
Diodes and overvoltage protection are located on the field-circuit rectifier (8).
Designs
The designs are characterized acc. to IEC 60034 Part 7 / DIN EN 60034-7. Other designs require agreement.
Design (code) Code I (International Code II (International Mounting)*
Mounting)
B3 IM B3 IM1001
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B3 / B5 IM B35 IM2001
B20 IM B20 IM1101
B14 / B20 IM B24 -
B5 / B20 IM B25 IM2001 / IM1101
* The meaning of the specified number codes can be obtained from the tables 847.2-852.2 in the book
"Einführung in die DIN-Normen" ("Introduction to DIN standards) (2001), Peter Kiehl (publisher).
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Design (code) Code I (International Code II (International Mounting)*
Mounting)
B16 IM B16 IM1305
B2 IM B2 IM1205
* The meaning of the specified number codes can be obtained from the tables 847.2-852.2 in the book
"Einführung in die DIN-Normen" ("Introduction to DIN standards) (2001), Peter Kiehl (publisher).
Table 2: Designs as per IEC 60034 Part 7 / DIN EN 60034-7
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3.4.2.2 Excitation systems
Gensets from MTU Onsite Energy use different generators with different types of excitation systems.
Characteristic SHUNT PMG AREP®
Engine starting ca- Medium High High
pability
Short-circuit capaci- Not applicable up to 300% up to 300%
ty
Short-circuit protec- Available Not applicable Not applicable
tion
Susceptibility to High Low Low
non-linear load
Voltage build-up Via remanence Via permanent magnet Via remanence
Power supply for Dependent on gen- Independent of generator volt- Independent of generator volt-
voltage regulator erator voltage age age
Number of rotating Low High Low
parts
Length of generator Low High Low
Operational life Optimal Reduced Optimal
Accessibility (for Optimal Reduced Optimal
maintenance)
Reliability of voltage Reduced Optimal Reduced
build-up
Load acceptance Reduced Optimal Optimal
Costs Low High Medium
Shunt-wound generator
A self-excited generator in which the field winding and armature winding are connected in parallel. The power
supply of the automatic voltage regulator (AVR) is branched off via a transformer at the generator.
PM generator (PMG)
A generator that is separately excited by a permanent magnet (PM). The power supply of the automatic volt-
age regulator (AVR) is single-phase or three-phase.
The automatic voltage regulator receives constant voltage and is thus independent of the generator.
AREP® generator
A generator that is separately excited based on the AREP® (Auxiliary Winding Regulation Excitation Princi-
ple).
The excitation current of the AVR is thus independent of voltage fluctuations (harmonics).
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3.4.2.3 Degrees of protection
The degrees of protection are identified by one digit respectively that precedes the letters IP (Ingress Protec-
tion):
• 1st code digit is the degree of touch and foreign body protection
• 2nd code digit is the degree of water protection
The degree of protection of the standard version is IP 23 acc. to IEC 60034 part 5/DIN EN 60034-5. In-
creased protection against oil vapors and dust can be achieved by using filters at the air inlet.
Degree of protection IP 43 is achieved using special filters on the driving end and non-driving end.
Two variants are offered for degree of protection IP 44:
• Implementation by D and N-side pipe connection. The cooling air is supplied from a dust-free room.
• The generator has a completely self-contained internal cooling circuit. The cooling air is cooled by external
media
Increased dust protection IP 54 can be achieved by additional bearing seals.
Thermal classes and insulation classes

The temperature increase determines the maximum kVA power of the generator. The temperature increase
is determined by the insulating system used.
For rotating electrical machines, separate temperature limit values are specified in the standard IEC
60034-22. The following limit values apply specifically to generators used for gensets from MTU Onsite Ener-
gy:
Component Thermal class H
R* ETF**
Winding of machines <5000 kW > 125 135
200 kW
Winding of machines <6000 kW 130 -
*R = resistance
**ETF = built-in temperature sensor
Insulating materials in generators and other electrotechnical devices age at high temperatures. IEC 60085
governs the temperature stability of different insulating materials and insulating systems and organizes them
in thermal classes. These categories specify the sustained utilization temperature at which the insulation ma-
terials still possess 50% of their original insulating properties after 20,000 hours (half-life period). The saved
temperature specifications are the maximum temperatures that are permitted at rated power.
If a longer operational life is to be achieved at the same operating temperature, an insulating material from a
higher thermal class will have to be used. In this way, the theoretical operational life is increased.
Limits on the temperature increase depending on the insulating system (acc. to IEC 60034-22):
Thermal class Maximum permissible continu- max. temperature according to
ous temperature DIN EN 61558, DIN VDE 0570
Y 95 °C -
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A 105 °C 100 °C
e 120 °C 115 °C
B 130 °C 120 °C
F 155 °C 140 °C
H 180 °C 165 °C
200 - 200 °C
220 - 220 °C
250 - 250 °C
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It is permitted for the maximum temperature to be increased in standby gensets (acc. to IEC 60034-22):
• Class H insulating system: 205 °C temperature increase at 40 °C ambient temperature
• Class F insulating system: 175 °C temperature increase at 40 °C ambient temperature
The following illustration shows the half-life period of insulating systems.
Figure 27: Half-life periods of insulating systems

1 Hours of operation 3 Class F 5 Standby power class H
2 Class B 4 Class H
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3.4.3 Fuel System
3.4.3.1 Fuel system – Description

NOTE: The configuration or inspection of the system must be carried out by a specialist company / appraiser
with knowledge of the respectively valid local legal specifications, guidelines and standards.
The following components for the fuel system are included in the scope of delivery of the engine-generator
set from MTU Onsite Energy (some are optional):
• Gas train
• Gas mixer
• Turbocharger (depending on version)
• Electronic gas control valve
• Mixture cooler (depending on version)
• Throttle flap
• Deflagration protection (only with biogas)
Other components for the fuel supply form part of the infrastructure .
The engines have a control unit that takes over the mixture and speed control including various monitoring
functions.
In the 400 series, the gas mixer works according to the venturi principle, i.e. the gas is added to the combus-
tion air at the narrowest point of a venturi nozzle.
In the 4000 series, control of the engine power is via a performance map-controlled mixture and speed con-
trol system by means of a gas control valve and the throttle flaps downstream of the has cooling system.
The mixture is compressed by the exhaust turbocharger and then cooled in the mixture cooler. Depending on
the version, the first stage of the mixture cooling is integrated in the engine coolant circuit.
The fuel gas must correspond to the MTU Fluids and Lubricants Specifications (→ Page 64). In the case of
biogas, sewage gas and landfill gas, pay particular attention to the maximum permitted relative humidity be-
cause it is necessary to ensure that no condensation can arise in the gas train.
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3.4.3.2 Gas train
To guarantee optimum operation of the gas engine, a separate gas train must be provided for each gas en-
gine. This must ensure that the requirements of the burnable gas in accordance with MTU Fluids and Lubri-
cants Specifications are observed independently of the influence of possible disturbance variables.
The following section provides a description of a typical fuel supply system. Deviating gas trains are also pos-
sible provided that the gas engine requirements are still observed. The presentation applies similarly to other
models.
Figure 28: Gas train

1 Gas filter 4 Deflagration protection 7 Gas pressure monitor
2 Pushbutton tap 5 Gas pressure regulator 8 Double solenoid valve
3 Pressure gauge 6 Gas control valve 9 Leak check
The gas train corresponds to applicable international standards and directives.
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3.4.3.3 Gas mixer
Gas mixer for 400 series
After the fuel gas leaves the gas train, it is mixed with the combustion air using a gas mixer. The genset must
be operated with a constant gas pressure and a constant gas temperature.
The gas mixer works according to the venturi principle. This means the air flows through a constriction, and
then through a diffuser. The gas is added to the combustion air at the narrowest point. Acceleration in the
constriction (nozzle) creates underpressure, as a result of which the gas is sucked in automatically from a
gap at the narrowest point in the cross-section. During the subsequent deceleration, the pressure increases
once again until almost attaining atmospheric pressure, as a result of which the mixing process takes place
without any major pressure loss.
This mixing type offers the advantage that the gas/air quantity ratio always remains the same even if the air
mass flow rate changes due to a power change. It is a precondition for precisely maintaining the gas-to-air
mixing ratio that the gas pressure before the admixture gap must be the same as the air pressure before the
venturi tube.
Gas mixer for 4000 series

After the fuel gas leaves the gas train, it is mixed with the combustion air using a gas mixer. The genset must
be operated with a constant gas pressure and a constant gas temperature.
A TecJet ® has mixer from Woodward with electronic gas control valve is used. The required gas volume is
transmitted via a CAN bus from the engine to the TecJet ® gas control valve. In addition, the TecJet ® gas
control valve automatically compensates for changes in the gas pressure and gas temperature.
The advantage of this system is that combustion is very lean during engine operation and emissions are
therefore very low.
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3.4.3.4 Installation of the gas system
During installation and maintenance of the gas system (line and components), specifications according to
DIN, DVGW, TRD, PED etc. must be observed.
Among other things, refer to:
• DIN 6280-14: Cogeneration power plants (CPP) with internal combustion reciprocating piston engines: ba-
sic principles, requirements, components, version and maintenance
• DIN 6280-15: Cogeneration power plants (CPP) with internal combustion reciprocating piston engines:
Checks
• DIN EN 12261: Gas Pressure Regulators for Inlet Pressure up to 100 bar
• DVGW - G 490 Gas Pressure Regulator Stations for Inlet Pressures up to 4 bar
• DVGW - G 491 Gas Pressure Regulator Stations for Inlet Pressures from 4 to 100 bar
• DVGW - G 495 Gas System Repair
• DVGW - G 496 Pipelines in Gas Systems
• DVGW - G 600 Technical rules for Gas Installations
• TRD 412 Gas Firing in Steam Boilers
Notes on installation and commissioning:
• The corresponding connections at the engine are shown in the engine installation drawing and the P&I
diagram.
• To ensure stable control, the length of the connecting lines between gas pressure regulator in the fuel line
and the engine connection must be minimized (max. 2 m).
• The connection from the engine to the gas train on the plant side or fuel line must be established free of
tension by means of a resilient fuel and flame resistant hose. The installation guidelines of the manufac-
turer must be observed.
• The fuel lines must be installed free of tension, chafing and kinks. In this regard, the requirements of
DVGW or TRD must be observed.
• The requirements of the blow-off and relief lines are defined in the DVGW guideline G496 as follows:
– Blow-off, relief and breather lines in modified plants must be routed to the atmosphere. The outlet
openings of these lines must be arranged such that the ignitable gas mixtures do not reach walk-in
areas, neighboring rooms or sources of ignition. They must be protected against clogging.
– Blow-off and relief lines must not be merged together with breather lines in a collecting line. If several
blow-off, relief or breather lines are combined in collecting lines, the operation of the connected devi-
ces must not be impaired.
• A shutoff device must be provided in the connecting line outside the installation compartment in a safe
place. This shutoff device must be manually operable and easily accessible in case of emergencies.
• No ignitable mixtures must be generated in the installation compartment. Avoidance through, e.g. gas de-
tector, increased air throughput, etc.
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3.4.4 Intake Air System
3.4.4.1 Intake air system – Description

The adequate supply of an engine-generator set with combustion air is the basic prerequisite for reaching full
rated load and efficient combustion. The air inlet system supplies the engine with filtered air for the combus-
tion process. Depending on the environmental conditions, as an option the intake air can be cooled or heat-
ed up before entry to the engine.
An engine-generator set from MTU Onsite Energy is equipped as standard with a suitably designed and in-
stalled intake air system.
The following components for the intake air system are included in the scope of delivery of the engine-gener-
ator set from MTU Onsite Energy (some are optional):
• Air filter
• Maintenance/differential pressure indicator
Components that form part of the engine as standard are not considered here.
Other components for the ventilation system form part of the infrastructure (→ Page 120).
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3.4.4.2 Air filter
The air filters protect the engine against abrasive dirt particles contained in the air and which cause in-
creased engine wear. Materials that contain rust, mill scale or other deposits, must not be installed in the air
inlet system because they could cause increased engine wear.
For engine-generator sets from MTU Onsite Energy, dry-paper elements with a reinforced design are recom-
mended. For short operating times (e.g. standby operation), regular or single-stage filters are normally suffi-
cient.
Air filters with dry-paper elements must meet the following requirements:
• Sufficient filtering capacity
• High mechanical stability
• Sufficiently long service life
• Ease of physical and visual access for maintenance tasks with sufficient space to change the filter ele-
ments
The selection of filter is based on the engine model, application, operation environment and desired filter
service life. The service life of the filter is proportional to the dust retention capacity of the air filter. High-
performance air filters with safety elements are recommended for standby and continuous operation.
The selection of a suitable air filter depends on the following factors:
• For the maximum air requirement of the engine and limit values for differential pressure with clean and
contaminated air filter, refer to the TEN data for MTU engines)
• Desired service life
• Operating environment (e.g. dusty, damp or salty atmosphere)
• Recommendations of the air filter manufacturer
High-performance air filters from MTU Onsite Energy are available upon request. Further details on this are
available from your local MTU Onsite Energy authorized dealer or sales partner.
If you have any questions about air filter selection including the necessity of oil-bath air filters, consult your
local authorized dealer or sales partner from MTU Onsite Energy.
A description of the air filters is provided in the operating and maintenance manual.
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3.4.4.3 Differential pressure
A maintenance/differential pressure indicator must be installed in the air intake system for displaying main-
tenance requirements of the air filter.
Intake air differential pressure is an important parameter for the intake air system. A high intake air differen-
tial pressure can result in insufficient air being made available for combustion. A high air filter resistance can
contribute to a high intake air differential pressure. The following factors can contribute to a high intake air
depression:
• Small pipe diameter
• Too many bends in the system
• Long pipe between air filter and turbocharger inlet
• High intake resistance of air filter
Excessive intake air depression can result in:
• Reduced power
• Poor fuel utilization
• High combustion temperatures
• Overheating
• Reduced service life of engine
Calculation of differential pressure in intake air system

The differential pressure of the intake air system equals the sum of the individual differential pressures in the
system, which are caused by rain caps, inlet shrouds, air filters and pipelines.
The total value of the intake air differential pressure in mbar (inH2O) is calculated by adding together the
following differential pressures:
• Differential pressure of the rain cap or inlet shroud
• Differential pressure of the prefilter
• Differential pressure of the air filter
• Differential pressure of the pipelines
• Other differential pressures
For the initial configuration of the intake air system, base the sizes on the diameter of the turbocharger inlet.
If the intake air differential pressure exceeds the max. permissible level, the pipes must have larger dimen-
sions or the pipework routing has to be changed. If the dimensions of silencers, filters, pipelines and air in-
takes into the engine room are insufficient, the intake air differential pressure will increase. To keep the val-
ue within the permitted range, it is necessary for correctly dimensioned components to be installed and for
them to be maintained accordingly. The air inlet system must contain as few pipe bends and obstacles as
possible and must have short pipe sections.
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3.4.5 Exhaust System
3.4.5.1 Exhaust system – Description

Stationary engine-generator sets that are operated inside a building require an exhaust system to conduct
the exhaust gas away safely and to keep not only the noise emissions but also the temperature at a permit-
ted level.
The exhaust system must be developed and designed with care to receive full engine power. The exhaust
system fulfills the function of directing the exhaust gases to a suitable outlet point and of lowering the ex-
haust sound level to a permissible level.
The following components for the exhaust system are included in the scope of delivery of the engine-genera-
tor set from MTU Onsite Energy (some are optional):
• Exhaust bellows
• Exhaust pipework after exhaust pipe bellows
• Exhaust silencer
• Exhaust gas heat exchanger
• Catalytic converter
Information on components of the exhaust system can be found here (→ Page 127).
Technical data and requirements of the exhaust system are available in the TEN data for MTU engines. This
data can be found in the Technical Evaluation Network via the MTU Business Portal.
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3.4.6 Lube Oil System
3.4.6.1 Lube oil system

Correct function of the lube oil system is necessary for long and trouble-free engine operation. The engines
have autonomous pressurized circulation lubrication via gear-driven oil pumps. The oil pan serves as the lube
oil reservoir container.
Refer to the TEN data available via the MTU Business Portal for detailed operating data of the lube oil sys-
tem.
Operation is only permitted with the lube oil qualities approved for the gas series 400, 4000 (DK-BS-001, DK-
BS-002). Only the connections provided on the genset for oil monitoring, emptying, additional filtering and
preliminary lubrication are allowed to be used. Interventions or changes to the lube oil system within the
engine are not permitted.
The following components for the lube oil system are an element of the engine-generator set from MTU On-
site Energy:
• Lube oil filter
• Oil level monitoring
• Oil priming/draining (only with 4000 series)
• Lube oil cooler
Other components for the lube oil system form part of the infrastructure (→ Page 137).
Lube oil filter

Additional oil filtering must be provided in systems for continuous power or with very high capacity utiliza-
tion, as well as if it is necessary to extend the oil change intervals. The selection and use of additional lube
oil filtering must be agreed with MTU.
Oil level monitoring

The oil level can be checked manually using a dipstick fitted to the engine as standard, and the oil can also
be replenished automatically if required. Oil level measurement and oil replenishment are described in the
MTU Onsite Energy operating and maintenance manuals.
With electric oil level monitoring, a separate level tank as a communicating vessel allows a settled oil level to
be measured even when the engine is running.This facility is fitted as standard on MTU Onsite Energy gas
engines.
Note: For configuration of the oil level monitoring, bear in mind that the oil level is lower when the engine is
operating compared to when it is at a standstill, due to the circulating oil volume in the engine.
Oil priming
Gensets in the 4000 series have external oil priming for building up the oil pressure in the gas engine prior to
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start.
The need for oil priming depends on what the genset is used for. Oil priming is not absolutely necessary.
Oil priming is required in the following exceptional circumstances:
• Gensets with very frequent starts
• Gensets with very short ramp-up times
• Gensets in which the stationary engine is exposed to vibration
• Gensets installed at an extreme angle
The type and duration of oil priming are project-specific in each case and must be agreed with MTU Onsite
Energy. Only intermittent oil priming is allowed to be provided. Continuous oil priming is not permitted due to
the risk of potentially excessive lubrication of the engine.
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Lube oil cooler
In the lube oil cooler, the lube oil of gas gensets is cooled down by the engine coolant or the heating water.
Depending on the size of the lube oil cooler, the oil temperature will be approx. 15 K hotter than the coolant
inlet temperature (measured in the oil pan).
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3.4.7 Cooling System
3.4.7.1 Cooling system – Description

A correctly configured cooling system is essential for satisfactory performance and reliability of the engine.
Extensive knowledge of the application, the mission profile and ambient conditions of the genset is necessa-
ry for configuration and combination of the entire cooling system.
The engine coolant heat has to be dissipated to meet the temperature requirements for engine coolant and
mixture cooling system. Heat is dissipated from the engine in four ways:
• Engine coolant
• Mixture coolant
• Exhaust
• Radiated heat
The cooling circuits are required to cool the engine. The engine coolant circuit dissipates heat absorbed by
the engine oil. This system is operated at relatively high temperatures and is therefore also designated the
high-temperature coolant circuit (HT circuit) (operating pressure 6 bar).
The coolant for cooling the gas mixture after compression in the turbocharger is cooled via the mixture cool-
ant circuit. This system operates at low temperatures and is therefore also designated the low-temperature
coolant circuit (LT circuit) (operating pressure 6 bar).
The exhaust gas emerges from the engine at a temperature of several 100 degrees Celsius and therefore has
to be discharged quickly (flue). In cogeneration power plants, the exhaust gas heat is used to operate the
heating water system of the customer (→ Page 94).
The radiated heat is the residual heat that is not absorbed by the coolant and thus heats up the installation
compartment of the genset. The radiated heat must be taken into account because, in many cases, it has an
effect on the air temperature for the fan and cooler, e.g. if the cooler is installed in the same installation
compartment as the engine-generator set.An aeration and ventilation system ensures that, among other
things, the radiated heat is discharged from the installation compartment.
Water with corrosion protection and antifreeze added to it is used as coolant. The additives used must com-
ply with the specifications in "Fluids and Lubricants Specifications.
In cases in which a roof installation is necessary for constructional reasons or if the genset and cooling sys-
tem are far apart, the maximum permissible system pressure in the engine and mixture coolant circuit (tech-
nical description) must be observed.
The following components for the cooling system are an element of the engine-generator set from MTU On-
site Energy:
• Engine coolant heat exchanger or fan cooler
• Preheater for coolant (4000 series standard; 400 series optional)
• Mixture cooler (400 series partly without)
Other components for the coolant supply system form part of the infrastructure (→ Page 141).
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Engine coolant circuit

The engine coolant circuit has a complete internal pipework system so that the lube oil heat and the first
stage of the mixture cooling heat are transferred via the coolant to an external closed overpressure system
with external electric circulating pump via a plate-core heat exchanger or fan cooler. As an option, the first
stage of the mixture coolant can be decoupled (HT decoupling).
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Mixture coolant circuit
The main component of the mixture coolant circuit is mixture cooler installed on the engine (only with 4000
series engines). When coolant is applied to this cooler, the mixture is cooled and the heat is transferred to an
external closed overpressure system with external electric circulating pump.
Due to the low temperature level in the LT circuit, this heat can usually not be used and is therefore dis-
charged via the fan cooler.
The following points must be observed when configuring the coolant circuits:
• The coolant used is a mixture of corrosion inhibitor, antifreeze and water. The additives used must comply
with the provision of the Fluids and Lubricants Specifications (Fluids and Lubricants Specifications
A001064/..for diesel gensets or DK-BS0001 and DK-BS0002 for gas gensets).
• It is advisable to install a filling and drain point at the lowest point of the cooling system. Ensure that there
is no residual coolant in the cooling system after the coolant has been drained.
• The cooling system must be designed as a closed overpressure system and must be equipped with a dia-
phragm expansion tank, safety pressure valve and a minimum pressure limiter.
• The temperatures and pressure listed in the engine operating instructions must be observed.
• The high points of the system must be equipped with a sufficiently dimensioned venting device.
• The use of zinc in coolant-carrying components is not permitted.
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3.4.7.2 Preheater
For a reliable start, the engine coolant must have a sufficient temperature (usually 40 °C). If this is not guar-
anteed, the engine coolant circuit must be preheated. An electric preheater is installed in the engine for this
purpose, which is supplied from the existing power supply network during engine standstill. The preheating
circuit must be circulated with a coolant pump. The configuration data of the pump can be obtained from the
TEN data (Technical Evaluation Network in the MTU-Business Portal) .
The preheating temperature depends on several influencing variables:
• Engine version
• Outdoor or indoor installation
• Moving/non-moving air
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3.4.7.3 Engine coolant heat exchanger
The engine heat (HT circuit) is transferred and via a plate-core heat exchanger to the customer's heating wa-
ter system and, where applicable, the exhaust gas via the exhaust gas heat exchanger.
The following must be observed in this case:
• The engine inlet temperature must be regulated to a constant value (see respective technical description).
• The max. speed of the temperature change in the heating water circuit must not exceed 10 K/min.
• The heating water return temperature must be observed (see technical description).
• The requirements of the heating water quality must be observed to prevent damage to the plate-core heat
exchanger.
• The heating circuit must be equipped with a safety device in accordance with PED and EN regulations.
All coolant circuits must have protection in accordance with the respectively applicable national require-
ments. The following standards can be referred to in Europe:
• Heating water temperature max. 100 °C: EN 12828
• Heating water temperature ≤ 110 °C: EN 12828
• Heating water temperature > 110 °C: EN 12953
However, the specifications defined by the approval authorities are definitive!
If the heat exchanger is not supplied by MTU Onsite Energy, it must be configured by a specialist company.
It is also possible to transfer the exhaust heat directly (via the exhaust gas heat exchanger) to the custom-
er's heating water system. However, in this case the exhaust gas heat exchanger may require a higher heat-
ing water quality. The quality of the heating water must therefore be determined and checked in operation to
prevent damage to the exhaust gas heat exchanger.
The following values must be known to do this:
• Engine coolant flow rate
• Engine coolant heat including tolerance (see technical description)
• Engine coolant inlet and outlet temperature (see technical description)
• Antifreeze concentration in the coolant in percent by volume (vol.%)
• Maximum permissible pressure loss of heat exchanger (must be considered when configuring the circulat-
ing pump)
• Operating pressure, maximum permissible pressure
• Contamination margin
For detailed specifications, please contact MTU Onsite Energy.
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3.4.7.4 Fan cooler
To keep engine temperatures constant, a mechanical thermostat (heat-expansive wax controller) or electron-
ically-controlled 3-way valve must be provided in the engine coolant inlet. If the cooling system is not sup-
plied by MTU Onsite Energy, it must be configured by a specialist company.
The following values must be known to do this:
• Engine or mixture coolant heat including tolerance (see technical description)
• Engine coolant inlet and outlet temperature (see technical description)
• Engine coolant volume flow
• Mixture cooler inlet temperature (see technical description)
• Mixture coolant volume flow (see technical description)
• Antifreeze concentration in the coolant in percent by volume (see Fluids and Lubricants Specifications)
• Maximum permissible pressure loss of fan cooler (must be considered when configuring the circulating
pump)
• Operating pressure, maximum permissible pressure
• Maximum permitted operating temperature
• Site altitude, intake and/or ambient temperature and other conditions at place of installation (salty at-
mosphere, sandy, extreme snowfall, etc.)
• Sound emission values to be observed
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3.4.8 Starting Equipment
3.4.8.1 Starter system

The scope of delivery of most engines marketed by MTU includes a single electric starter, although on re-
quest a double or redundant starting system can be fitted.
Electric starting system

The electric starting system comprises the following components:
• Starter
• Battery charger
• Batteries
• Starter relay
The batteries store electrical energy. An electric starter converts the electrical energy into mechanical ener-
gy and then transfers the mechanical energy to the engine as torsional force. The electrical energy generated
by the battery charger is transferred to the battery where it is stored for subsequent use. Cables connect the
battery to the starter and the battery-charging generator or battery charger to the battery.
Electric starter cables must be protected against mechanical damage. Ensure that permissible bending radii
are observed.
Please contact MTU Onsite Energy for information about special versions.
To keep the cross-section of the starter cable as small as possible, the battery must always be positioned
near to the starter.
Starter decoupling and blocking

To avoid possible damage, all starter systems must be disengaged automatically after engine start.
Engines equipped with an electric starting system typically use an overrunning clutch to disengage the drive
pinion of the starter motor. This clutch protects the starter from damage doe to overrevving.
Once the engine has been started, it is necessary to make sure that the starter can not be activated inadver-
tently.
All starting systems should have a blocking monitoring function.
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3.4.8.2 Batteries
Gensets from MTU Onsite Energy use batteries for operation of the starter and the control system.
Ba terries are not usually delivered for the American market.
Lead-gel batteries are normally used, which increases operational reliability and prevents expensive mainte-
nance intervals.
Batteries for 4000 series

MTU Onsite Energy supplies batteries, battery cables, terminal caps and frames as part of the standard
equipment of the engine-generator set. However, tariff restrictions on deliveries abroad must be observed
which means that the scope of delivery can deviate.
For engine-generator sets with MIP stand-alone, batteries, battery cables, terminals caps or frames are not
included in the delivery.
Starter battery
MTU Onsite Energy uses lead-gel batteries (Exide® Technologies). Depending on the engine model, one or
two starter batteries are installed:
• 8V / 12V: 1 starter battery A412 180 Ah, 12 V
• 16V / 20V: 2 starter batteries A 412 each with 180 Ah, 12 V
Control system battery

MTU Onsite Energy uses lead-gel batteries (Exide® Technologies) A512 with 40 Ah at 12 V.
Batteries for 400 series

MTU Onsite Energy supplies batteries, battery cables, terminal caps and frames as part of the standard
equipment of the engine-generator set.
With 400 series gensets, the battery supplies the starter and the control system.
MTU Onsite Energy uses lead-gel batteries (Exide® Technologies) A412 with 180 Ah at 12 V.
For engine-generator sets with MIP stand-alone, batteries, battery cables, terminals caps or frames are not
included in the delivery.
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3.4.8.3 Battery charger
Battery charger
The battery charger (a DC voltage power supply unit) monitors and charges the starter batteries of the gen-
set.
For engine-generator sets with MIP stand-alone, a charger is not included in the scope of delivery.
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3.4.9 Power Electronics
3.4.9.1 Controllers
MTU Interface Panel – MIP
The MIP (MTU Interface Panel) contains the genset controller with generator monitoring system and synchro-
nization. The MIP is the standardized interface between genset and the MMC (MTU Module Control).
The MIP is the electrical controller of all drives on the baseframe, i.e. of the genset. These include:
• Controls (EMERGENCY-STOP buttons)
• Computer-programmable-controller (PLC), programming acc. to IEC 61131-3
• EMM energy measuring module (generator/mains power protection, synchronization device), VDEW-con-
form
• Communication with ADEC engine governor and EMU Engine Monitoring Unit via hardware signals and
CAN-BUS
• Interface for connecting to external systems (floating contacts)
– Main measurement voltage (synchronization / mains power protection)
– Busbar voltage (synchronization / mains power protection)
– Generator circuit breaker feedback (On, Off, Fault)
– Mains circuit breaker feedback (On, Off, Fault)
– Differential protection, ground-fault protection, remote
– Mains power protection, remote
– Mains failure test, remote
– Manual EMERGENCY-STOP feedback circuit, remote
– Generator voltage with medium voltage
• Activation of the auxiliary drives at engine-generator set
The MIP supplies the following output signals:
• Activation of generator circuit breaker (GLS On, GLS Off)
• Activation of mains circuit breaker (NLS On, NLS Off)
• Start request for auxiliary drives, general
• Open backup switch
• Manual EMERGENCY-STOP to remote
The MIP is fitted in the gas gensets in some control versions (→ Page 108).
Programmable logic controller – PLC

Manufacturer: B&R GmbH
Integrated functions:
• Recording of measurement data (analog and digital) of the engine-generator set
• Start and stop procedure
• Control of module-internal auxiliary drives
• Closed-loop controls (power control)
• Evaluation of all fault and operational messages
• Analog value monitoring
• Backup of parameters, measurement and operating data
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Monitoring features:
• Overfrequency (ANSI: 81, IEC: f>)
• Underfrequency (ANSI: 81, IEC: f<)
• Overvoltage (ANSI 59, IEC: U>)
• Undervoltage (ANSI: 27, IEC: U<)
• Normal dependent overcurrent (ANSI: 51, IEC: l>t>)
• Overcurrent (ANSI: 50, IEC I>>)
• Overload (ANSI: 32 F, IEC: Pf>)
• Reverse power (ANSI: 32R/F, IEC: Pr, Pf>)
• Unbalanced load (ANSI: 46, IEC: 12>)
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Synchronization function:
• Synchronization (ANSI: 25, IEC: --)
Operating conditions (deviations depending on selected options)

• Ambient temperature: 10-40 °C
• Air humidity: 10-80%, non-condensing
• Site altitude above sea level: 0-1500 m
• Switch cabinet IP54
MTU module control – MMC

The MMC is the electrical controller of all drives that are not activated by the MIP and thus also customer-
specific functions. The MMC contains the required cogeneration power plant controllers and network moni-
toring system including the visualization and user interface. The MMC switch cabinet on the plant is secured
separately on the ground.
Functions include:
• Heating water system (e.g. pumps, regulating valves)
• Emergency cooling water system (e.g. pumps, fans, regulating valves)
• Compartment temperature control (e.g. fans, flaps)
• Buffer tank
• Gas compressor
• Customer-specific systems
The MMC functions exclusively in conjunction with an MIP. There are exceptions for CHP and container var-
iants. Here, the MIP functions are integrated in the MMC.
The MMC includes the following components:
• Industrial PC (IPC) with touchscreen and various interfaces, operating system Microsoft Windows ®
• Controls (key switch, pushbuttons, EMERGENCY STOP buttons)
• Expansion boards of the RPS controller with digital and analog inputs and outputs
• Interfaces for connecting to external systems (floating contacts)
• Control of peripheral drives by floating contacts or power sections
The MMC switch cabinet is installed separately on the ground (→ Page 108).
RPS functions
The RPS communicates with the IPC via Ethernet.
Integrated functions:
• Recording of measurement data (analog and digital) of the basic scope and the selected options
• Optionally selected control functions of external auxiliary drives
• Optionally selected control modes
• Evaluation of fault and operational messages (saving and display at IPC)
• Analog value monitoring
• Backup of parameters, measurement and operating data
Monitoring features
The following functions are implemented with an MMC in addition to the generator protection and synchroni-
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zation with the energy measuring module. All recorded signals and faults are visualized in the MMC.
Mains power protection:
• Overfrequency (ANSI: 81, IEC: f>)
• Underfrequency (ANSI: 81, IEC: f<)
• Overvoltage (ANSI: 59, IEC: U>)
• Undervoltage (ANSI: 27, IEC: U<)
Switch cabinet size

MMC basic scope: 800 x 2000 x 600 mm (W x H x D)
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Operating conditions (deviations depending on selected options)
• Ambient temperature: 10-40 °C
• Air humidity: 10-80%, non-condensing
• Site altitude above sea level: 0-1500 m
• Switch cabinet IP54
MTU control system – MCS

With the MCS as instrumentation and control, it is possible to control several MMCs and thus implement
energy and heat management. This controls higher-level functions.
These include:
• Higher-level compartment ventilation
• Power system demand control
• Buffer evaluation
• Mains switch control
The MCS comprises the following components:
• Industrial PC (IPC) with touchscreen and various interfaces, operating system Windows®
• Computer-programmable-controller (PLC), programming acc. to IEC 61131-3
• Various interfaces
• MTU Synchronization & Protection (MSP)
For plants with a single genset, the MCS functions can be implemented in the MMC (→ Page 108).
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3.4.9.2 Control versions – Gas genset
The appropriate control version (0 - 6.3) must be selected according to the number of gensets and the re-
quired usage type.
Type of service One genset (gas) Several gensets (gas) Several gensets (gas+diesel)
Isolated 1, 2, 3, 4, 5, 6 5, 6 5, 6
Grip parallel 0 0, 5, 6 6
Emergency power 1, 2, 3, 4, 5, 6 5, 6 5, 6
Table 3: Operating modes

The possible control versions are shown below.
Control version according to operating mode 0

Permits grid parallel operation of a genset. No standby power possible.
Scope of delivery
• MIP
• MMC (optional)

Permits parallel grid operation or standby power operation of a genset. An uninterruptible power supply is
guaranteed in case of mains failure. There is an interruption when mains power returns.
Scope of delivery
• MIP
• MMC (optional)

Permits parallel grid operation or standby power operation of a genset. An uninterruptible power supply is
guaranteed in case of mains failure and when mains power returns.
Scope of delivery
• MIP
• MMC (optional)

Permits parallel grid operation or standby power operation of a genset. There is an interruption of the elec-
tricity supply in case of mains failure and when mains power returns.
Scope of delivery
• MIP
• MMC (optional)
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Permits parallel grid operation or standby power operation of a genset. There is an interruption in case of
mains failure. An uninterruptible power supply is guaranteed when mains power returns.
Scope of delivery
• MIP
• MMC (optional)

Control version according to operating mode 5.1
Permits parallel grid operation or standby power operation of several diesel and gas gensets. An uninterrupti-
ble power supply is guaranteed in case of mains failure and when mains power returns. The power monitor-
ing controls the gensets if there is a mains failure.
In grid parallel operation, energy and/or thermal management via MCS is required (demand control, buffer
control, etc.).
Scope of delivery
• MIP
• MMC (optional)
• MCS

ble power supply is guaranteed in case of mains failure and when mains power returns.
control, etc.).
Scope of delivery
• MIP
• MMC (optional)
• MCS

Permits parallel grid operation or standby power operation of several diesel and gas gensets. There is an in-
terruption of the electricity supply in case of mains failure. An uninterruptible power supply is guaranteed
when mains power returns.
control, etc.).
Scope of delivery
• MIP (also stand-alone)
• MMC (optional)
• MCS

Permits parallel grid operation or standby power operation of several gensets. An uninterruptible power sup-
ply is guaranteed in case of mains failure and when mains power returns.
In grid parallel operation, energy and/or thermal management via external process control (customer's proc-
ess control) is required (demand control, buffer control, etc.).
Project adaptations with inventory are necessary with this version.
Scope of delivery
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• MIP
• MMC (one per genset)
• External process control (customer's process control)

ble power supply is guaranteed in case of mains failure and when mains power returns.
In grid parallel operation, energy and/or thermal management is required (demand control, buffer control,
etc.).

Mains circuit breaker control, utilization control necessary.
Scope of delivery
• MIP (also stand-alone)
• MMC (optional)

Permits parallel grid operation or standby power operation of several gensets. There is an interruption of the
electricity supply in case of mains failure. An uninterruptible power supply is guaranteed when mains power
returns.
etc.).
Scope of delivery
• MIP
• MMC (one per genset)

Permits parallel grid operation or standby power operation of several diesel and gas gensets. There is an in-
terruption of the electricity supply in case of mains failure. An uninterruptible power supply is guaranteed
when mains power returns.
etc.).
Scope of delivery
• MIP
• MMC (optional)
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3.5 Infrastructure
3.5.1 Assembly instructions
Requirements
Further information on the description of the customer interfaces and commissioning of the desired genset
is available in the following documents via the MTU Business Portal:
• M060775 for gas gensets of the 4000 series (MTU Onsite Energy, Augsburg)
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3.5.2 Engine-Generator Set Room
3.5.2.1 General requirements

The statics of the building must have a rating sufficient for the plant. If necessary, consult a structural engi-
neer. The load bearing components (ceiling, wall, floor) in the installation compartment must be fire-resistant
such that the building can resist a fire for at least 90 minutes. The foundation must be flat and such that it
can safely support the weight of the genset and system components. The weight of the genset can be ob-
tained from the technical data sheet. With regard to the vibrations caused by the genset, the foundation
must be designed in accordance with the foundation data sheet.
Sufficient openings must be provided to install and remove components. The requirements of the louver
dampers are described in the Ventilation chapter. The building / container must have sufficient protection
against lightning strokes. Specifications of insurance providers must be researched. The plant must be inte-
grated in the on-site lightning protection system.
The technical data sheet and the foundation data sheet must be observed.
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3.5.2.2 Requirements for premises
To increase the level of work safety with regard to noise emission and vibration emission, it is recommended
to install the genset and the switchgear in separate rooms, if possible. In so doing, the risk of the control
cabinets overheating will be reduced.
Due to the noise emission, a sound-insulating enclosure is recommended for the genset. There must be suffi-
cient lighting in the installation room and the room for the switchgear. The use of halogen spotlights with hot
surfaces and high rates of heat loss is not permitted due to the risk of fire.
Emergency exits and escape routes must be well-lit and appropriately marked. Emergency exits and escape
routes must not be blocked by cables or suchlike (pipes, hoses). The escape routes from other rooms must
not pass through rooms for switchgear or the installation room. Escape doors must open in the direction of
escape.
It must be possible to lock the installation room and the switchgear room, so that access by unauthorized
persons can be prevented.
If the genset or the module is delivered by MTU Onsite Energy as a container solution, the container must be
secured such that willful damage or unauthorized access by third parties cannot occur.
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3.5.2.3 Installation compartment – Requirements
Requirements of the installation compartment
For safe operation of the genset, the installation compartment must be suitably arranged. During the plan-
ning phase, you should already check whether compliance with further official requirements is necessary.
The installation compartment must be large enough to permit easy operation and maintenance of the mod-
ule / genset as well as sufficient ventilation. The dimensions of the genset are shown in the planning draw-
ing. The space required for movement during operation, maintenance and repair is also shown in the plan-
ning drawings. These dimensions required for movement must be observed in all circumstances. In addition
to the dimensions of the genset and space required for movement, the space requirements of the peripheral
connected systems (coolant circuits, exhaust system, oil system) must also be taken into consideration. Sur-
faces subject to heating must be insulated. The space required for insulation, the required minimum distance
to walls and between the individual objects must be guaranteed. The erection of climbing aids must be possi-
ble. Ventilation ducts must be at least 0.7 m above the top edge of the mixture cooler.
Observe the planning drawing from MTU Onsite Energy.
Lifting tools for maintenance work

Lifting equipment suitable for the heavy component parts of the engine (turbocharger, mixture cooler, etc.)
must be provided in the installation compartment. The weight of the genset can be obtained from the techni-
cal data sheet.
Series 400:
• In installation of a crane rail is recommended.
Series 4000:
• In installation of a crane rail is necessary.
Observe the planning drawing from MTU Onsite Energy and the technical data sheet.
Fire protection requirements

Potential fire loads in the installation compartment must be minimized. In particular, no combustible material
must be deposited or stored in installation compartment. The minimum distance required for fire protection
reasons between pipelines, other components and walls subject to heating must be observed. Wall ducts
with pipelines and cables must be sealed off accordingly. Measures must be introduced for early detection of
fires and smoldering fires, e.g. the installation of a fire detection system. Suitable extinguishing agents must
be available (fire extinguisher, fire extinguishing system).
The corresponding national legislation and local specifications on fire protection must be observed.
Explosion protection (OEG)

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The Fluids and Lubricants Specifications must be observed.

The gas supply system before the inlet to the gas train must be designed to prevent the ingress of oxygen. If
necessary, process-related access points such as condensate traps must be monitored.
According to the state of technology, suitable measures must be introduced because the possibility of an
explosion in the exhaust tract can not be excluded.
More detailed requirements are described in the Exhaust system chapter.

Exterior explosion protection (UEG)
The gas supply, including gas train, in the installation compartment must have a leaktight design and must be
checked on a regular basis for continuous leak-tightness. With circulation air systems, an exhaust air duct
must be provided through which gas, in the event of a gas leakage, can be safely discharged. As a supple-
mentary protective measure, the installation of a gas detector to be integrated in the plant control system is
necessary. For this purpose, at least one gas warning sensor must be installed above the gas engine in direc-
tion exhaust air. Dead corners in the installation compartment without a flow should be avoided where possi-
ble because gas from leaks can accumulate there. If this is no longer possible for design-related reasons, gas
warning sensors should be installed here. The room ventilation must be dimensioned such that, in the event
of leakages on gas-carrying parts, a potentially explosive atmosphere can not be created. The gas-air mixture
must be safely discharged directly to the atmosphere. For more detailed requirements of the ventilation sys-
tem, refer to the Ventilation chapter.
Noise protection
Exact details on noise emission can be obtained from the technical data sheet. In accordance with these
values, suitable measures must be taken, e.g. noise insulating paneling of the genset (acoustic enclosure) or
acoustic boards in the installation compartment. The respective national legislation and local specifications
must be observed.
Vibration
The genset must be mounted on insulating boards to reduce the vibration transfer to the building and foun-
dation. The length and number of the boards to be provided depends on the size and weight of the genset
according to the planning drawing from MTU Onsite Energy. External vibrations must not act on the genset
because this affects the natural frequency of the genset, which can be increased. This can result in failure or
breakage of components.
Frost protection
The temperature in the installation compartment must not fall below 5 °C in any section. It may be necessa-
ry to install a heater.
Environmental protection
The installation compartment must comply with local specifications of water protection (e.g. VAwS - Ordi-
nance on Installations for the Handling of Substances Hazardous to Water and on Specialist Firms, WHG -
Water Resources Act). When using an extended oil system, the tank(s) must be jacketed and equipped with a
leak indicator system. Otherwise the installation compartment must be designed as an oil-tight trough.
Any other possible specifications (installation of an oil separator or a neutralization system for accumulated
exhaust gas condensate) must be requested from the local authorities.
Equipotential bonding, protective conductor and grounding

For the selection and installation of electrical equipment, grounding arrangements and protective conduc-
tors, see DIN VDE 0100-540.As the design of the equipotential bonding and the protective conductor de-
pends on the form of the local power grid, it is not possible to provide details at this point. Only generally
applicable information independent of the form of power grid can be provided at this point.
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Equipotential bonding:
Apart from the module frame and heat module frame, all other metallic, electrically conductive components
must be included in the local equipotential bonding. This includes heating water pipes, gas line, exhaust sys-
tem and cable trays. Several connection points for equipotential bonding have already been prepared at the
module frame. A steel strip embedded in the foundation can be very easily connected at one of these posi-
tions. The equipotential bonding is implemented from the module frame to the generator frame via flexible
connecting lines.
Protective conductor:

The protective conductor must be connected in every case to the housing of the generator. Grounding of the
generator neutral point depends on plant-specific factors. The local specifications of the power supply com-
pany or the safety regulations must be observed to ensure that grounding is carried out correctly.
Central grounding point
State of the art is the version with a central grounding point. This reliably prevents stray currents. If a central
grounding point is used, there is only one connection between PEN (protective conductor with neutral con-
ductor function) and ground. The complete run of the PEN conductor must be insulated. For networks with
decentralized power supply, a further central ground point is possible. The two areas with central grounding
points must not be operated in parallel.A central grounding point must be provided in the installation com-
partment.
Manual emergency stop

In hazardous situations, it must be possible to shut down the plant safely by means of a manual emergency-
stop button outside the installation compartment.
Installation compartment warnings

The installation contains electromagnetic fields. For this reason, persons with implanted medical devices,
e.g. pacemakers, must not enter the installation compartment and switchgear rooms. Appropriate warnings
must be affixed at the doors to the switchgear room and installation compartment. MTU Onsite Energy in-
cludes a set of "Warnings" stickers in the delivery for the installation compartment.
Further instruction plates

An instruction plate for safe conduct in the event of a fire or gas alarm must be provided. Also required is an
instruction plate noting that the ventilation powers up in the event of simultaneous gas alarm and manual
emergency stop.
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3.5.2.4 Requirements of switchgear room
To guarantee accessibility, it must be possible to open all switch cabinet doors up to at least 90 °C.
The ambient conditions (dust, moisture) of the switchgear room must be suitable for the versions of the
switch cabinets.
Cabinet Degree of protection Temperature range
MIP IP54 0 - 40 °C
MMC IP54 0 - 30 °C
HA IP54 0 - 30 °C
GLF IP2X 0 - 35 °C
Table 4: The switch cabinets supplied by MTU typically meet the following requirements:
Due to special requirements, deviating values are possible project-specifically and which are noted on the
corresponding circuit diagram documents. The switch cabinets are usually designed for air humidity of 50%
at 40 °C and 90% at 20°C. Corrosive or aggressive substances in the atmosphere can cause damage to elec-
trical component. Suitable precautions must there be taken on site to prevent a corrosive or aggressive at-
mosphere in the switchgear room.
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3.5.2.5 Installation recommendations
Gas train
The gas train can be floor-mounted or suspended from a wall or the ceiling. Install the gas train so that there
is a sufficient amount of space available for the performing of maintenance tasks. The highest part of the gas
train is the gas pressure regulator. Consequently, the minimum distance to the ceiling of the installation
room is determined by the position of the gas pressure regulator. The space requirement for maintenance
tasks at the gas pressure regulator is to be taken into account. This space requirement is indicated on the
planning drawing and the technical data sheet for the gas pressure regulator.
Note:
• When performing maintenance tasks at the genset, there must be a sufficient amount of headroom.
• Never position the gas train directly above the engine, but to one side.
• The gas hose between the pressure regulator and the gas metering valve must not exceed a certain
length.
• 4000 series: Maximum length of gas hose: 3 m
• Series 400: Maximum length of gas hose: 2 m
• The curved part of the hose must run perpendicular to the engine shaft
• Install the gas train so that the connection points for the flushing and wastewater lines are easily accessi-
ble.
• Information on the permissible bending radius of the gas hose and the height difference between the en-
gine and the gas train can be found on the planning drawing.
Comply with the operating manual and the manufacturer’s technical data sheet.
Batteries
The batteries are positioned next to the genset in the battery racks.
Notice:
• MTU Onsite Energy uses only maintenance-free, lead gel batteries.
• The batteries must not be placed in the vicinity of the flywheel housing.
• This area must remain free for maintenance purposes.
• Do not expose starter batteries to extreme temperatures.
• The temperature should not exceed 45 °C.
• The battery racks must not block any escape routes.
It is recommended to position the batteries as close as possible to the starter or in front of the
generator in the fresh-air section of the engine room, and such that there is easy access for
maintenance tasks.
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3.5.3 Fuel supply system – Gas genset
In most cases, a gas genset is directly connected to a gas line. This means no further components are re-
quired in the infrastructure for the fuel supply system.
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3.5.4 Ventilation system
3.5.4.1 Ventilation
Adequate ventilation of the engine room is important for correct operation of the genset. The ventilation sys-
tem carries out two functions. Firstly, it supplies the engine with combustion air, and secondly it cools the
genset and removes any potentially explosive gases.
When configuring the ventilation system, it is necessary to take account of the conditions in the installation
compartment and the environment of the system (e.g. compass direction, emissions sources, acoustic re-
quirements, etc.). The technical data of the genset and the operating conditions required for the genset can
be found in the technical description and the operating instructions.
The main tasks of the ventilation system are:
• Supplying the engine with combustion air
• Controlling the compartment temperature at a constant value (between 25 °C and 30 °C (guidance value)
• Dissipating the cooling load of the engine and all built-in components in the installation compartment
• Guarantee of the minimum and maximum intake air temperature during engine start
• Ensuring the required air quantity is provided for adequate dilution of the air in case of a gas alarm (gas
leak in the installation compartment)
• Ensuring the required quality of the intake air
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Figure 29: Compartment ventilation

1 Supply air 2 Exhaust air
120 | Ventilation system | E 2015-08

For safe and trouble-free engine operation, the combustion air temperature and thus the supply air tempera-
ture must be controlled to a constant value. This can be carried out by a ventilation system with variable
volume flow (frequency-controlled fans) or circulation air control (addition of warm exhaust air or compart-
ment air to the supply air) in winter. In summer the combustion air is supplied to the engine at outside tem-
perature.
In the operating status, the plant must guarantee that combustion air volume (see technical description) is
supplied to the installation compartment. The air pipework in the installation compartment must guarantee
the following:
• Uniform ventilation in the installation compartment
• No heat nests
• No formation of ignitable gas/air mixture
The air pipework must be designed to ensure that a short circuit between the supply air and exhaust air is
not possible and sufficient heat dissipation at the components takes place. If necessary, the supply air can
be introduced through a vent grill in the installation compartment. The supply air is blown on the generator
side into the compartment.
If there is a risk of frost and at temperatures below 10 °C in the installation compartment with the engine
stationary, the louver dampers (external and escaping air) must be closed to ensure that the room remains
frost-free.
When designing the ventilation system, the limit values from the technical description must be taken into
consideration.
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3.5.4.2 Combustion air
Combustion air supply
The following factors influence the power of the engine:
• Drawn-in combustion air volume
• Air temperature
• Air pressure (site altitude)
The combustion air is supplied via the installation compartment ventilation. In the case of increased dust
load, the supply air openings of the engine room must be provided with suitable filters. MTU gas engine must
only be operated with the dry-type single air filters installed ex works. These are installed directly on the en-
gine (see planning drawings). The removal height for filter change must be taken into consideration.
The connection of the system must guarantee that impermissible overpressure does not build up at the in-
take hose. The connection must be designed as a flow safety device. The intake line must only be extended
or connected to customer-provided devices following approval by MTU Onsite Energy. In winter operation,
ensure that the minimum intake air temperature is guaranteed.
Following consultation and written authorization by MTU Onsite Energy, in special cases the combustion air
can also be drawn in directly from the atmosphere.
If this is the case, the following items must be taken into consideration when configuring the intake side for
the combustion air:
• Warm air must not be drawn in
• No exhaust gas can enter the filter
• Filter replacement is possible
• Protection against water ingress is guaranteed
• The permissible pressure loss before the air filter in accordance with the technical description us ob-
served.
The filter design also influences the engine noise level. Our noise spectra are based a measurement with the
dry-type single air filters included in the delivery. The resilient connecting parts (sleeves, hoses) must be re-
sistant to fuel, lube oil and temperatures up to +120 °C. Deformation resistance to underpressure is a pre-
requisite.
No materials must be used on the intake air side that are coated with rust, scale or other deposits and which
could lead to premature engine wear. Arrange the filters such that no dust or objects can enter the intake
area during filter change.
Combustion air volume

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3.5.4.3 Compartment air
Compartment air supply
The building openings for supply and exhaust air should preferably be provided with weather guards including
small animal protective grills and electrically actuated louver dampers.
The supply air opening should be positioned such that no foreign bodies or pollutants (exhaust gas, solvent
vapors etc.) can enter the installation compartment and that the supply air drawn in is as cool as possible
(e.g. influence of horizontal-core radiator)
In accordance with the noise requirements, appropriate silencers must be designed for the supply and ex-
haust system. When doing this, the influence of other possible noise sources (exhaust flue, horizontal-core
radiator, etc.) and the flow noise must also be taken into consideration.
Due to sound radiation from the installation compartment, acoustic paneling (e.g. double-skin acoustic insu-
lation, noise suppression coating, etc.) for the ventilation ducts and components is necessary.
Underpressure ventilation
Underpressure ventilation is the simplest type of ventilation. In this case, front-end coolers or electric fans
(horizontal-core radiators) extract the hot air from the engine room. The resulting underpressure allows a rel-
atively even supply of fresh air into the engine room.
The supply air and exhaust air openings should be arranged so that the room ventilation achieved is as effec-
tive and even as possible. To avoid high pressure losses in weather guards, the supply air openings should be
made sufficiently large for the airspeed not to exceed 4 m/s.
The permissible underpressure in the installation compartment must not undershoot 80 Pa. When doing this,
the maximum permissible underpressure of the room enclosure surfaces must be observed. The advantage
of the system is that, for example, with a gas alarm gas does not usually overflow into neighboring building
parts.
Overpressure ventilation
The supply air is drawn in via fans from the outside and forced into the installation compartment. The pres-
sure loss on the exhaust air side is taken over by the supply air fan.
The maximum permissible overpressure in the compartment must not exceed approx. 50 Pa. When doing
this, the maximum permissible overpressure of the room enclosure surfaces must be observed.
The advantage of the system is that no contamination from outside can enter the installation compartment
(dust load, pollutants). Contamination in the supply air must be removed by filters.
The system can be designed as a circulation air system (two-stage) or with variable volume flow.
System with supply and exhaust air fans (MTU recommendation)

The supply air is drawn in via a supply air fan from the outside and forced into the installation compartment.
The exhaust air is drawn in via an exhaust air fan from installation compartment and blown out into the at-
mosphere.
Due to the design of the system, depending on the installation conditions a slight overpressure or underpres-
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sure can be maintained in the installation compartment. When doing this, the maximum permissible over-
pressure or underpressure of the room enclosure surfaces must be observed.
The system can be designed as a circulation air system (two-stage) or with variable volume flow.
Mixed air system (with circulation air share)

The fan has a two-stage design and the supply air temperature is regulated to a constant value by the circula-
tion air flap (addition of exhaust air or room air from the installation compartment). The stages of the fan are
switched according to the exhaust air temperature (or, if necessary, the room temperature).

The outside and exhaust air louver damper has a positive opening function to guarantee three-fold air change
in the installation compartment and the combustion air supply for the engine. With this system, the plant is
always operated at a constant supply air temperature in winter.
In the event of a gas alarm, the fan is switched immediately to the higher stage and the louver dampers are
opened (or the circulation air flap is closed).
Ventilation system with variable volume flow (fan FC-controlled)

The fan is controlled by a frequency converter (FC) steplessly according to the exhaust or intake air tempera-
ture or the room temperature.
The minimum air volume is set at the control system. In the event of a gas alarm, the fan is switched immedi-
ately via the side input of the FC to maximum volume flow.
Compartment air volume

In all cases, the cool supply air should first flow axially over the generator and then over the engine. Avoid an
air short-circuit, i.e. the supply air and exhaust air openings must be positioned so that no (warm) exhaust air
can be sucked back in through the supply air opening.
If silencers have to be installed to reduce noise due to statutory regulations, their dimensions must be se-
lected according to the following factors:
• Available space
• Airflow
• Damping factor
Configuration
The air requirement for adequate ventilation of the compartment in which the engine-generator set is instal-
led is calculated as follows:
V = (Q * 3600) / (cpm * Δt * ρ) + C
V: Air throughput (m3/h)
CS: Heat to be dissipated (kW)
• Diesel engine (manufacturer's specifications)
• Generator (manufacturer's specifications or 8% power)
• Exhaust pipe (approx. 2% of engine power for 10 meters insulation pipe)
• Additional heat sources
cpm: Specific heat capacity of air (1,005 kJ/kg °C)
Δt: Temperature difference (between inlet and outlet temperature of cooling air) approx. 15 °C to 18 °C
(59 °F to 64 °F)
ρ: Air density (at sea level)
• 1.29 kg/m3 at 0 °C (32 °F)
• 1.25 kg/m3 at +10 °C (50 °F)
• 1.20 kg/m3 at +20 °C (68 °F)
• 1.16 kg/m3 at +30 °C (86 °F)
• 1.13 kg/m3 at +40 °C (104 °F)
• 1.09 kg/m3 at +50 °C (122 °F)
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• 1.06 kg/m3 at +60 °C (140 °F)

C: Combustion (m3/s)
• Depending on engine type

3.5.4.4 Air pipelines
Air pipelines and associated fittings must be configured so that flow resistance is kept to a minimum, and
reliable sealing is guaranteed.
Air pipes must be designed as short as possible. The system must be designed with as few pipe bends and
obstacles to the flow as possible. Smooth pipe elbows must be used, whereby the ratio of bending radius to
pipe diameter must be at least 2.0 (however, preferably 4.0).
Air ducts must be kept well away from heat sources such as exhaust manifolds etc. Suitable insulation or
jacketing must be used to keep the radiated heat from these sources to the inlet system as low as possible.
Guarantee accessibility of maintenance-related parts.
Specifications for pipeline materials

Seamless pipes made of aluminum or aluminum-plated steel must be used. The pipe ends must have a bead
of at least 2.3 mm (0.09 inch) for holding hoses/hose clamps.
Pipelines made of stainless steel are recommended for applications in which the intake air contains relatively
low or high salt concentrations.
Glass-reinforced plastic pipes are also permitted between the air filter and compressor inlet of the turbo-
charger.
MTU Onsite Energy recommends not installing segment elbows with fewer than five segments.
Diffusers
Hose connections
Hose connections must be designed according to the following recommendations:
• Simple (non-reinforced) hoses: For the connection of rigid duct segments with little relative movement,
which are exactly aligned and only bridge small distances.
• Short reinforced hoses: For connection of duct segments with significant relative movement or misalign-
ment. These requirement are met by the high-quality beaded hoses.
• Clamps with a constant tightening torque guarantee security and prevent the connections from detaching.
• Minimize the number of hose connections to reduce leaks and the associated entry of unfiltered air in the
intake section.
MTU Onsite Energy shall not issue approval for the use of hoses with a coil spring insert. Hoses used in the
intake system must be designed such that they can withstand the operating conditions. The hoses must have
the following characteristics:
• Fuel- and lube oil-resistant
• Resistant to underpressure up to 12.5 kPa (50 in. H2O)
• Temperature-stable up to 150 °C (302 °F)
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3.5.4.5 Safety requirements of the ventilation
Explosion - measures in event of gas discharge
During installation and operation of gas engine inside buildings, heating plants or similar constructions (e.g.
containers), measures must be introduced to prevent or limit the formation of a potentially explosive atmos-
phere in the event of damage.
The installation compartment contains sources of ignition (hot surfaces, electrical components and parts,
mechanically generated sparks) which, in the event of damage, could result in the ignition of a potentially
explosive atmosphere.
For this reason, it is essential that measures are taken in the installation compartment to prevent the crea-
tion of a potentially explosive atmosphere in the event of gas discharge.
This means:
• Adequate fresh air supply and its mixing during operation in the installation compartment. Accumulation
of operation-related, unavoidable leaks on vibrating components with no permanent technical sealing
must be prevented by the ventilation.
• With circulation air systems, the share of fresh air in the supply air must be at least 25%.
• Uniform purging of the installation compartment to prevent the formation of ignitable gas-air mixture in
dead corners. If there are dead areas in the installation compartment without a flow, further gas warning
sensors must be installed.
The control system and monitoring system (switchgear) of the cogeneration power plant must be provided
with circuits that trip or implement the following measures in the event of a gas alarm.
Measures in case of gas alarm:
• Run-up of the ventilation system to 100% or ventilation switch-over to the high stage
• Opening of the louver dampers (open when de-energized) and closing of the circulation air flap (closed
when de-energized), if available.
• Exhaust air duct for air exchange in the event of a gas alarm at engine standstill
• The individual systems and components (ventilation system or gas system) must also be designed, built,
checked and serviced to ensure that the tripped and initiated measures are continuously effective in case
of a fault.
400 series
For naturally-aspirated engines in the 400 series, the installation of a gas detector is not necessary because
operation does not result in the discharge of mixture or fuel gas downstream of the safety gas train (zero
pressure regulator).
The intervals specified in the Operating Instructions for a professional leak check of the gas train must be
observed for all plants in all circumstances. Additional requirements apply to the positioning of pressure reg-
ulator stations inside the installation compartment.
Measures in case of fire

In case of a fire, the ventilation and fire protection flaps must be closed and the ventilation must be shut
down.
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Prioritizing between gas alarm, fire alarm and manual emergency stop
In the event of a gas alarm, fire alarm and manual emergency stop, the double solenoid valves of the gas
train are closed and the fuel supply is thus stopped. In case of a simultaneous gas alarm, fire alarm and man-
ual emergency stop, the gas alarm has the highest priority. As an additional protective measure, the ventila-
tion system is powered up to 100%. The supply air flaps and exhaust air flaps are forced open and the air
circulation flap, if available, is closed. When automatic extinguishing systems with CO2 are used, the prioriti-
zation has to be re-evaluated.

3.5.5 Exhaust System
3.5.5.1 Requirements of the exhaust system

The exhaust system fulfills the function of directing the exhaust gases to a suitable outlet point when they
leave the engine and of lowering the exhaust sound level to a permissible level.The exhaust gas is discharged
through the exhaust pipes and silencer to the atmosphere.
The exhaust system for a genset from MTU Onsite Energy must function under a wide range of ambient con-
ditions. The system is exposed to rain and snow, and is subject both to thermal and mechanical stresses.
Stationary gensets that are operated inside a building require an exhaust system to conduct the exhaust gas
away safely and to keep not only the noise emissions but also the temperature at a permitted level.
The complete exhaust system including all built-in components such as the silencer, catalytic converter and
heat exchanger must be configured to be corrosion- and impact-resistant and pressure-tight.The exhaust sys-
tem must be installed load-free on the engine or exhaust turbocharger. Force must not be introduced. De-
tails on possible explosion in the exhaust system are provided in the Operating Instructions and the installa-
tion conditions.
For technical data and requirements on the exhaust system, refer to the TEN data for MTU engines. This data
can be found in the Technical Evaluation Network via the MTU Business Portal.
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3.5.5.2 Configuration of the exhaust system
Configuration
The configuration of the exhaust system is determined by legal regulations relating to noise protection and
explosion protection (for gas gensets) as well as the requirements of the genset in question. The most impor-
tant parameter in the calculation is the exhaust back pressure.
For exhaust lines, a flow velocity of approx. 40 m/s is recommended. The nominal widths of the pipes are
listed in DIN EN 10220.
Excessive exhaust back pressure leads to noise development, overload of the engine components and a pow-
er drop. As a result, the entire pressure loss of an exhaust line must be calculated as follows:
Δptot = (ΔpR x l) + ΔpK x n) + ΔpF + ΔpS
whereby:
• Δptot: Total pressure loss
• ΔpR: Pressure loss in the pipeline
• ΔpK: Pressure loss at the elbows
• ΔpD: Pressure loss at the silencers
• ΔpS: Pressure loss at other components
• l: Length of the pipelines
• n: Number of elbows
Note that the permitted pressure of the engine should not be exploited to the full. The pressure should not
exceed 75% of the maximum permitted value, so as to minimize maintenance costs and breakdowns.
Calculating pressure loss in pipelines

To calculate the pressure loss in the pipelines, the following parameters must be determined:
• Pipe roughness (mm)
• Total length of pipe system (m)
• Pipe bend 90° - ratio (R / d)
• Number of pipe bends 90°
• Zeta value for pipeline outlet
Calculating pressure loss in exhaust silencer

To calculate the pressure loss in the silencer, the following parameters must be determined:
• Zeta value for exhaust silencer
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3.5.5.3 Exhaust pipe bellows
Exhaust pipe bellows

The exhaust pipes must be decoupled from the engine to permit relative movement and reaction of the en-
gine to torque and thermal expansion. The purpose of flexible connections is to permit relative movement of
the engine, to compensate for thermal expansion and to allow alignment of the engine to the exhaust pipes.
The recommended flexible connections are multi-walled bellow expansion joints. They must be able to com-
pensate for deformation in longitudinal direction (axial offset), minor bending (angular offset) and thrust
(transverse offset). Deformation through torsion must be avoided.
Figure 30: Permissible misalignment of bellows

1 Axial offset 2 Angular offset 3 Transverse offset
The axial expansion range of flexible connections in the exhaust system must not be fully utilized. Angular
and transverse offset can not be ignored completely because assembly tolerances and engine operation al-
ways have an effect on the flexible connections. Angular and transverse offset reduces the axial expansion
absorbing capacity of expansion bellows for exhaust pipes. A permissible value for angular offset on expan-
sion bellows for exhaust pipes supplied by MTU Onsite Energy is ±5 °C (±9 °F). For engine-generator sets
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with expansion bellows provided by the customer, refer to the supplier's documentation for the permissible
angular offset.
The thermal expansion of exhaust pipes as a function of the temperature is shown in the diagram below.

Figure 31: Thermal expansion over temperature
1 Austenitic steel A Thermal expansion in
2 Ferritic steel mm/m
B Temperature difference in
°C
The temperature difference B is the difference between an ambient temperature of 20 °C (68 °F) and the
maximum exhaust pipe temperature.
Flexible connections or expansion bellows for exhaust lines must be expanded prior to installation. The re-
quired pretension for the expansion bellows in the exhaust line is derived from the distance between fixed
points and the thermal expansion as a result of the exhaust gas temperature. The following illustration shows
an expansion bellows for installation in an exhaust line.
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Figure 32: Flexible connection or expansion bellows for exhaust line
1 Cold state (installation tem- 4 Installation state (bellows 7 Installation size/installation
perature) pretensioned) length
2 Warm state (engine opera- 5 Nominal size/nominal width 8 Clamping pieces
tion) 6 Expansion range
3 Tension-free state (before
installation)
Note: The three clamping pieces divided over the circumference serve as assembly aids (tube, wooden slat,
etc.).
Bellows assembly
• The bellows must be pretensioned during installation. The corresponding installation dimensions can be
obtained from the engine installation drawing or the exhaust pipe bellows drawing.
• Two linear dimensions are usually specified in the bellows drawings:
– Bellows nominal size or installation length
This dimension is based on the bellows in a neutral, untensioned state and serves for control purposes
only.
– Bellows installation dimension or installation length
During installation, the bellows must be pretensioned to the bellows installation dimension or installa-
tion length. During operation, the bellows is then largely free of stress.
After assembly of the exhaust line, the pretensioning dimension must be checked.
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The following must be observed to avoid frequently recurring assembly errors:
• Flexible connections or expansion bellows must be correctly installed between two fixed point to compen-
sate for thermal expansion.
• Prior to assembly, the exhaust pipe bellows must be inspected for transport damage.
• If exhaust pipe bellows are installed in parallel, ensure that all bellows have identical recovery properties
particularly if they are insulated.
• During assembly or maintenance work in the area of an expansion bellows in the exhaust line, ensure that
no damage can result which would impair the intended operating characteristics of the bellows.
• Exhaust pipe bellows must be protected against weld spatter.
• Ensure that electrical currents are not conducted through the exhaust pipe bellows (e.g. during welding
work).
• Keep expansion bellows free from foreign bodies such as dirt, insulating material, cement, etc. to ensure
unimpeded expansion/retraction of the bellows.
• In the case of exhaust pipe bellows with inner protective tube, ensure that the tube does not come into
contact with the exhaust pipe bellows during engine operation.
• After assembly, any clamps, assembly aids and transport locking devices that may be present must be
removed.
Exhaust pipework after exhaust pipe bellows

The exhaust pipework after exhaust pipe bellows can be designed as a separated or combined exhaust pipe.
Fastening points for the exhaust pipework must be provided on parts capable of bearing the load. They must
be secured in all three axes and arranged directly after the flexible bellows or the Y-pipe.
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3.5.5.4 Exhaust pipe
The exhaust line must be configured so the exhaust gas velocity does not exceed 20 to 25 m/s.
It is also necessary to consider noise generation due to flow noises (for details, see VDI 3733).
The complete exhaust system including all built-in components such as the silencer, catalytic converter and
heat exchanger must be configured to be corrosion-resistant and pressure-tight.
A resistance calculation of the exhaust system from the turbocharger to the atmosphere must be carried out,
taking the noise requirements into consideration.
The maximum permissible exhaust back pressure must be taken from the technical description.
The nominal width of the exhaust line is determined by:
• Exhaust gas volume
• Maximum permissible exhaust back pressure
• Noise requirements (guideline value of flow velocity approx. 20 to 25 m/s)
• Type of line routing
– Pipe lengths
– Radii of curvature
– Built-in components: Silencer, catalytic converter, exhaust gas heat exchanger, bypass flap, etc.
Additional requirements:
• Moisture must not be permitted to enter the engine through the exhaust line. The exhaust outlet must be
designed accordingly.
• Draining options must be provided in the exhaust line.
• Condensate must be routed to a collection container and disposed of correctly. Free condensate lines
must be protected by a water trap that corresponds to the maximum exhaust back pressure. An oil sepa-
rator must be provided for the condensate line.
• Small animal protective grills must be installed at the outlet.
• Ensure the design aids the flow.
• If the plant has several engines, ensure that no exhaust gas can enter the exhaust section of a stationary
engine. This can cause corrosion damage.
• Provide exhaust gas measuring connection for emission testing downstream of the engine or catalytic
converter or before the flue inlet.
• The insulation of the exhaust system must be designed for a maximum surface temperature of 60 °C.
• A separate exhaust pipe must be provided for each engine.
• The maximum permissible exhaust back pressure acc. to the technical description including the reserve
for contamination must not be exceeded.
• For 4000 series: If the maximum permissible back pressure is expected to be exceeded, the turbocharger
can be adapted in degrees. A maximum exhaust back pressure of 100 mbar, however, must not be ex-
ceeded.
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3.5.5.5 Exhaust silencer
Exhaust silencers reduce the noise level of the engine. The effect of exhaust silencers is based on the princi-
ple of absorption or reflection. Exhaust silencers must be installed in the exhaust pipework as near as possi-
ble after the engine-generator set to achieve the highest possible noise reduction.
Depending on the permissible sound pressure level, it may be necessary to install several silencers that can
be connected one after the other. During the design, note that the permissible exhaust back pressure must
not be exceeded.
The design of the silencers must be carried out by a specialist company. This requires the following details:
• Type of exhaust gas
• Exhaust gas volume
• Exhaust gas temperature
• Sound spectrum from engine (see technical description)
• Residual sound pressure level, either total sound pressure level or frequency-dependent
• Possibly geometrical specifications (e.g. inlet axial and outlet radial)
• Upright or side-mounted
• Pressure loss, maximum
The following illustration shows an example of an exhaust silencer.
Figure 33: Exhaust silencer

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1 Housing 3 Attachment point 5 Outlet with flange

2 Direction of exhaust gas 4 Inlet with flange a Exhaust gas
flow

3.5.5.6 Exhaust gas heat exchanger
After the turbochargers, the exhaust gas flows into the exhaust gas heat exchanger. Here, the heat is drawn
from the exhaust gas via the engine coolant.
For the configuration, production, commissioning and operation, the European Pressure Equipment Directive
(2014/68/EU) (or other regulations applicable in the respective country) must be applied.
Most of the exhaust gas heat exchangers are made of high-grade steel (1.4571). The maximum permissible
cooling of the exhaust gas is shown in the corresponding technical description.
For the configuration of the exhaust gas heat exchanger by a specialist company, the following details are
required:
• Exhaust gas characteristics: Temperature, mass flow, acid content (see DK-BS001 and DK-BS002)
• Exhaust gas heat quantity after engine (see technical description)
• Minimum exhaust gas temperature after exhaust gas heat exchanger (see technical description)
• Desired heating water temperatures
• Heating water pressure
• Possibly geometrical specifications (e.g. inlet axial and outlet radial)
• Upright or side-mounted
• Take service and maintenance ports into consideration
• Condensate drain line with water trap
• Measurement connections for temperature, pressure and max. exhaust gas pressure loss
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3.5.5.7 Exhaust flue
The flue/chimney is designed to ensure an unobstructed flow of the exhaust gases to the atmosphere.
In accordance with federal emission protection laws, when determining the minimum height of the flue not
only the emissions and the exhaust gas temperature but also the surrounding area (buildings, further chim-
neys, mountains etc.) must be taken into consideration.
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3.5.6 Lube Oil Supply And Disposal System
3.5.6.1 Oil line

Ensure that no contamination can enter the oil circuit. Newly installed oil lines must therefore be cleaned
prior to commissioning and checked for leaks.
The genset must be connected using oil and temperature-stable flexible hoses free of tension to the external
oil supply. The installation guidelines of the manufacturer must be observed.
Copper or galvanized steel pipes must not be used for the oil lines because zinc and copper have a harmful
on the additives in the engine lube oil.
All components and lines connected to the thrust side of the oil circuit must be designed for the respective
operating pressure.
The spray line is introduced to the tank at the top, 10 cm from the tank's top edge, and end below the lube
oil surface after refilling.
The lube oil replenishment device for the genset must be arranged approx. 2 cm above the tank bottom. The
distance between the spray line and removal line should be as far as possible to avoid short circuits between
the two lines.
Assembly of hoses
• Hoses must be installed such that they are not interfered with in their natural position or movement.
• Hoses must not be subject to tensile, torsional, compressive forces or other externally acting factors un-
less specially designed for this purpose.
• The smallest bending radius of the hose specified by the manufacturer must not be undershot (catalog
values provide information on this). Hoses must be protected against damage by mechanical, thermal or
chemical influences.
• Prior to commissioning, separable connections must be checked for firm seating.
• If there is visible external damage, the hose must not be put into operation.
• Before putting into operation, it may be necessary to clean the hose using a suitable method.
The specialist personnel tasked with installation must check the hoses for the following installation and oper-
ating conditions:
• Permissible medium
• Operating pressure min. / max.
• Operating temperature
• Flow conditions
• Pressure, nominal width and medium
• Correct installation of all hoses
• Wire braid
• Deformation of the hose
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3.5.6.2 Oil – Change
Used oil change
A lube oil pump draws the used oil from the engine oil pan. The is shut down again after a programmable
time.
Fresh oil filling

The fresh oil pump is switched on and the solenoid valves for the engine opened.
The min./max. contact (LS+/-) in the engine oil pan switches off the lube oil pump when the maximum filling
level is reached and closes the solenoid valves. Overfilling of the engine oil pan is prevented by an emergen-
cy shutdown via the max. contact (LSA+) and the programmable runtime monitoring system of the pump.
Oil quality
Oil quality is an important criterion for achieving optimum power, runtime and reliability of the genset. MTU
gas engines must be operated with MTU-approved lube oil that are listed in the MTU Fluids and Lubricants
Specifications DK-BS-0001 and DK-BS-0002.
Selection of a suitable engine oil is based on fuel quality, projected oil drain interval and on-site climatic con-
ditions. These parameters are also provided in the MTU Fluids and Lubricants Specifications DK-
BS-0001/0002 (for gas engine).
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3.5.6.3 Oil replenishment device
The oil reservoir in the oil pan us usually sufficient to achieve acceptable oil replenishment times. However,
special operating modes require an automatic oil replenishment device.
Equipping of the module / genset in continuous operation with an automatic lube oil replenishment device is
mandatory (and therefore always included in the scope of delivery). This device guarantees a constant level
of lube oil in the engine oil pan. A fresh oil tank including pump is recommended as a lube oil supply for
engine oil consumption.
Both the fresh oil and used oil tanks should be dimensioned such that filling or draining is only required two
to three times a year. The necessary lube oil change intervals and tank volumes con be obtained from the
documents DK-BS-0001 or DK-IB-0009.
The illustration shows an example of the oil system with fresh and used oil tank, fresh oil pump and safety
devices. The supply tanks are either jacketed or require a catch basin. A leak monitoring system is required
in both cases.
Figure 34: Oil replenishment device

1 Fresh oil tank 8 Non-return valve 15 min. contact, fresh oil tank
2 Used oil tank 9 Fresh oil pump 16 Overfill protection, used oil
3 Overfill protection ALARM 10 Supply, solenoid valves tank
4 min. / max. contact, oil re- 11 Oil pan draining pump 17 max. contact, used oil tank
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plenishment 12 Return, shutoff valve 18 Aeration and ventilation

5 min. contact ALARM 13 Overfill protection, fresh oil 19 Float content display, fresh
6 Gas engine tank oil tank
7 Engine oil pan 14 max. contact, fresh oil tank 20 Float content display, used
oil tank
21 Spray line
The relevant DIN and TRbF standards must be observed:
• DIN 6624 "Horizontal tanks made of steel"
• DIN 6625 "Square tanks made of steel"
• Technical regulations for combustible fluids (TRbF) 100 / 110 / 120 / 121 / 131 / 211 / 220 / 221 /
231
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For larger tanks, a tanker socket is recommended, which enables filling by means of a tanker by connecting
the tank's overfill protection with the pump on the tanker.
The specific engine oil consumption for the particular engine can be found in the TEN data (Technical Evalua-
tion Network in the MTU-Business Portal).
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3.5.7 Coolant Supply System
3.5.7.1 Configuration of the cooling system

Configuration of the cooling system
If the cooling system is not supplied by MTU Onsite Energy, it must be configured by a specialized company.
Refer to the TEN data for advice about this (see Technical Evaluation Network in the MTU-Business Portal).
The following values are required for cooler configuration:
• Thermal output from the engine or air/gas mixture to the coolant
• Mixture coolant inlet temperature
• Mixture coolant volume flow
• Engine coolant volume flow
• Engine coolant inlet and outlet temperature
• Antifreeze concentration in the coolant in percent by volume (vol.%)
• Maximum permitted pressure reserve (coolant side)
• Operating pressure, test pressure (water side)
• Maximum permitted operating temperature
• Ambient conditions (→ Page 65)
• Acoustic requirement, if necessary
The relationship between all components of the engine cooling system is expressed as follows:
dQ/dt = dm/dt x c x Δϑ
whereby:
• dQ/dt: Thermal output
• dm/dt: Mass flow
• c: Coolant heat capacity
• Δϑ: Temperature difference between engine coolant inlet and outlet
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3.5.7.2 Coolant pipework
All pipelines must be cleaned before first commissioning of the coolant circuit and must be free from resi-
dues.
The clearance of the coolant pipes must at least correspond to the cross-sections of the engine connections.
For larger line lengths, is necessary to recalculate the cross-section required.
The lines should be secured at sufficiently short intervals. When installing the lines, ensure that no air pock-
ets can be created.
High points in the pipe system must be provided with sufficiently dimensioned air chambers.
Material recommendation for the coolant pipelines
• Steel (acc. to DIN EN 10220, DIN EN 10305-1, ISO 4200)
• Galvanized pipes or containers are not permitted
Flexible connections
In all engines and gensets, flexible connections to the building must be provided directly after the engine
and, with double-elastic mounts, additionally directly after the baseframe. The installation instructions of the
manufacturers must be observed when doing this.
Note that MTU OE offers different scopes of delivery depending on the series. Check beforehand, therefore,
which connections are included in the standard scope of delivery.
The following items are suitable as flexible connections:
• Rubber long sleeve sockets
• Bellows
If the maximum coolant pressure is utilized, ensure that the rubber bellows is of a suitable high quality.
• Hoses
The flexible connections must be resistant to pressure (positive/negative pressure), high temperature, oils,
fuel as well as coolant additives.
Flexible connections must be arranged they can be visually inspected and renewed without difficulty. They
must be routed sufficiently far from moving parts and components with elevated temperature.
The flexible connections on the engine must be designed so that no impermissible forces can act on the en-
gine due to vibration and thermal expansion.
Lines between the engine and cooler or heat exchanger

The coolant lines must be routed over the shortest possible distance and without sharp elbows in order to
keep the flow resistance as short as possible.
The maximum permissible pressures are listed in the technical description.
Vent lines
Vent lines starting from the connections on the engine side must be routed to the diaphragm expansion tank
with a continuous upward slope. The vent lines must be routed into the headspace of the diaphragm expan-
sion tank.
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For complete venting of the systems, vent lines must be connected to all points provided for this purpose on
the engine and the mixture cooler.The vent lines must be routed to a common vent.
Important: Make sure there is adequate venting of the installed components such as cooler, preheater, etc.
Diaphragm expansion tank

Engine and mixture coolant circuits must be equipped with a closed diaphragm expansion tank in accord-
ance with DIN 4807. The expansion tank must implement the following functions:
• Receive coolant expanded through heating
• Provide coolant reserves in case of leakage losses
• Build up and maintain coolant operating pressure
142 | Coolant Supply System | E 2015-08

Installation is on the suction side of the pump. The design can be based on ZVH guideline 12.02. Note that a
possible pressure loss in the lines and built-in components between the diaphragm expansion tank and safe-
ty valve must be subtracted from the system's final pressure.
Safety valve
The closed coolant circuits must be protected by at least one safety valve against violation of the upper limit
of permissible operating pressure. Install an open diversion pipe in accordance with specifications to prevent
injury through escaping steam.
Low coolant protective device

To protect the gas engine against impermissible heating at low coolant levels, the cooling circuits must be
equipped with a low coolant protective device that shuts down the engine when the minimum coolant level is
undershot.
It must be installed at least 100 mm above the engine.
For gas gensets from MTU Onsite Energy (Augsburg), low coolant level protection is by means of pressure
monitoring
Cooler installation over engine

On plants with large distances and/or height distances between genset and cooling system, the maximum
permissible system pressure in the engine and mixture coolant circuit must be observed ((→ technical de-
scription)).
It may be necessary to provide an intermediate heat exchanger, or to install the circulating pump on the en-
gine outlet side.
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3.5.8 Cabling
3.5.8.1 Cabling and grounding

Cabling for engines / gensets / cogeneration power plant modules must only be carried out by specialist
companies familiar with the wiring of industrial plants.
Only the standards, regulations and specifications that deal specifically with the special condition involved
with engines / genset / cogeneration power plant modules will be mentioned.
It is necessary to ensure that cables and lines are suitable for the expected service life, and there is no risk
to operational reliability as a result of aging.
Pay attention to the following influences:
• Reduced current carrying capacity (buildups of dirt, external thermal influences)
• Mechanical, thermal and chemical influences
• Influences from the ground (embedded in sand or soft soil)
• Soil movement, vibration, shock
• Dynamic load due to maximum asymmetrical short-circuit currents
• Stray currents and corrosion
The following criteria and general conditions relating to the cabling must be considered.
• Cable groups
• Cable material
• Cable bundling
Grounding
Both the engine and the generator must be connected to ground potential by equipotential bonding strips on
the baseframe.
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3.5.8.2 Wiring – Standards and guidelines
The following list of standards, directives and regulations makes no claim to be complete.
Safety standards
DIN VDE 0100 Installation of power installations with nominal voltages of up to
1000 V
DIN VDE 0100-430 Installation of low-voltage plants, Part 4 to 43: Protective measures
against overcurrent
DIN VDE 0100-540 Low-voltage electrical installations, Part 5 to 54: Selection and erec-
tion of electrical equipment - grounding arrangements and protective
conductors
DIN VDE 0100-710 Low-voltage electrical installations - Requirements for special installa-
tions or locations - Part 710: Medical locations
DIN VDE 0100-718 Low-voltage electrical installations - Requirements for special installa-
tions or locations - Part 718: Communal facilities and workplaces
DIN EN 60204-1 (DIN VDE 0113) Safety of machinery - Electrical equipment of machines
DIN EN 50156-1 (DIN VDE 0116) Electrical equipment for furnaces and ancillary equipment
DIN VDE 0132 Firefighting and technical assistance in or near electrical installations
DIN VDE 0160 Electronic equipment for use in power installations
DIN EN 50272-2 Safety requirements for secondary batteries and battery installations,
Part 2 Stationary batteries
Guidelines
VdS 2025 Damage protection requirements for electrical cabling and laying oper-
ations
VdS 2097-8 Installation ducts and cable systems with function maintenance
Low Voltage Directive First ordinance on Equipment and Product Safety Act
2006/95/EC
EMC Directive 2004/108/EC Directive governing the electromagnetic compatibility of operating ma-
terials
Machinery Directive 2006/42/EC Equipment and Product Safety Act
Installation regulations
DIN VDE 0100-520 Low-voltage electrical installations - Part 5: Selection and installation
of electric equipment; Chapter 52: Cable and line installation
DIN EN 50173 Generic cabling systems
DIN EN 50174 Installation of communication wiring
DIN EN 61800-3 Adjustable speed electrical power drive systems - Part 3: EMC require-
ments
Line product regulations (for power plants)

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DIN VDE 0250 - Part 1 to 814 Insulated power cables

DIN VDE 0250-816 Heat-resistant silicone hoses
DIN VDE 0267 Halogen-free cables with improved characteristics in the case of fire
DIN VDE 0276 Power cables
DIN VDE 0298 Use of cables with insulated lines for power plants
DIN VDE 0472 Testing of cables, wires and flexible cords
E 2015-08 | Cabling | 145

Product regulations
DIN VDE 0604 / DIN VDE 0634 Electrical installation ducts
DIN VDE 0605 Electrical installation pipes
DIN VDE 0606 / DIN VDE 0609 Connecting material
DIN VDE 0619 Cable glands
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3.5.8.3 Cable list
Cable lists are usually enclosed with the circuit diagrams from MTU Onsite Energy. These cable lists basically
contain recommendations.
Local environmental conditions and specifications must be observed by the specialist company carrying out
the work. This relates both to the selection of cable types as well as the conductor cross-sections used.
The following illustration shows an extract from the cable list as an example.
Figure 35: Cable list from MTU Onsite Energy

1 Project name 5 Name 9 Reference terminal
2 Cable list 6 Function text, cable 10 Location code
3 Path 7 Cable type
4 Cable reference without 8 Reference target
plant and location code
The line name is composed of the following designations:
=cogeneration power Plant code

plant
+WSS Location code
-16W1 Equipment identifier
-e Group identifier
Composition of equipment identifiers

16 Page number that contains the first core of the cable or line
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w Code letter for cables and lines

1 Serial number on the circuit diagram page
Meaning of the group identifiers
-i Lines or cables used inside the switch cabinet
-m Module wiring: Lines and cables between engine, genset or cogeneration power plant module and
switch cabinet (is already carried out at MTU Onsite Energy)
-e External wiring: Cables and lines from switch cabinet to other customer-provided switch cabinets or
peripheral assemblies (e.g. cooler)
-g Cables and lines between MMC and MIP with gas gensets
with- These cables or lines are primarily included in the cable list of another switch cabinet and are men-
out tioned here because both cabinets are connected with one another
E 2015-08 | Cabling | 147

Notes on the cable cross-sections in the circuit diagram
The circuit diagram contains additional information on the conductor cross-sections for peripheral assem-
blies or power supplies that are further away from the switch cabinet.
Figure 36: Cable cross-section in the circuit diagram

1 In-series fuse 2 Cable cross-sections with
total length
Identification of the cables

The cables and lines are labeled in the same manner as the cable designations named in the circuit dia-
grams.
The use of captive cable designation on both cable ends is recommended. They should be able to withstand
the environmental conditions permanently.
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3.5.8.4 Line groups
Classification of the line groups
Line group 1 (LG1)
• Screened analog lines
• Screened lines for direct and alternating voltages ≤230 Volt
• Unscreened lines for direct and alternating voltages ≤60 Volt
Line group 2 (LG2)
• Unscreened lines for direct and alternating voltages >60 Volt and ≤230 Volt
Line group 3 (LG3)
• Unscreened lines for direct and alternating voltages >230 Volt and ≤1000 Volt
Line group 4 (LG4)
• Unscreened lines for direct and alternating voltages >1000 Volt
Conduits
MTU Onsite Energy has the following recommendations for conduits:
• Route each line group on separate cable bearers (cable lines, cable trays, cable troughs, cable conduits,
etc.).
• Route cables from different line groups separated by at least 10 cm from one another provided that they
are not installed in different insulating tubes or ducts or are separated from one another by rigidly instal-
led separating strips.
• Observe the minimum distances also at cross and approach points.
• LG1 and LG2 cables must not be routed directly beside LG3 lines. Always install LG4 cables in separate
cable bearers.
• Signal cables and the associated equipotential bonding must be kept as short as possible.
• Route all lines close to ground planes.
• Avoid cable and line extensions via terminals.
• All cables must be number based on the cable list (cable identification plates).
• Take specified bending radii of the cables used into consideration.
• When installing the cables, observe the respective installation conditions (e.g. ambient temperature, bend-
ing radius).
Cable material
The lines used must comply with valid, harmonized and national standards. The cables to be installed must
correspond to the intended purpose and type of installation and must be capable of resisting specific on-site
local influences (heat, oil, water, UV light, etc.).
Only flexible (or high-flexible for the generator) line must be used.
Cable cross-section for power cables must be defined by the company performing the work in accordance
with DIN EN 50565-1; DIN EN 50565-2 and/or IEC 364-5-523. The specifications in the circuit diagrams
must be checked by the company performing the work for compliance with the local situation. Reduction
factors must be taken into consideration in accordance with the local situation. VDE specifications 0100,
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0101, 0271 and 0250 must also be observed.

The electrical documentation (plant-specific) provided by MTU Onsite Energy contains a compilation of cable
proposals in the form of a cable list.
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Examples of cable types used
Line group 1 (LG1) screened
SIHCSI-O Silicone line
Cu-stranded conductor, tin-plated, finely stranded, non-halogen, increased ther-
mal stability
Conductor insulation and outer liner on silicone basis, screen braiding of tin-plat-
ed wires
NYSLYCYÖ or Oil-resistant control line
H05VVC4V5-K Cu-stranded conductor, bare, finely stranded
Conductor insulation and outer liner on PVC-basis, screen braiding of tin-plated
wires
Manufacturer designation, e.g. Ölflex Classic 140 CY.
LIYCY Control line
Cu-stranded conductor, bare, finely stranded
Conductor insulation and outer liner made of special PVC, foil wrapping, drain
wire, screen braiding of tin-plated wires
Manufacturer designation, e.g. Ölflex Classic 115CY or TRONIC-CY
MEGAFLEX 500-C Oil-resistant control line
Cu-stranded conductor, bare, finely stranded, non-halogen, weather- and UV-re-
sistant
Conductor insulation made of special polymer, outer liner non-halogen special pol-
ymer, screen braiding of tin-plated Cu-wires
Usage, e.g. in exterior area (cooler)
OZ-BL-CY Special PVC hoses with blue jacket
Cu-stranded conductor, bare, finely stranded
Conductor insulation made of special PVC, outer liner made of special PVC,
screen braiding of tin-plated wires
Usage in potentially explosive areas with ignition protection type
Manufacture designation, e.g. Ölflex EB CY
Line group 2 (LG2) unscreened

NYSLYÖ Oil-resistant PVC control line
unscreened
Manufacturer designation, e.g. Ölflex Classic 110
SiHF Silicone line
Cu-stranded conductor, tin-plated, finely stranded, non-halogen, increased ther-
mal stability
Conductor insulation and outer liner on silicone-basis
MEGAFLEX 500 Oil-resistant control line
sistant
ymer
Procedure: e.g. in exterior area (cooler)
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OZ-BL Special PVC hose with blue jacket

Cu-stranded conductor, finely stranded
Conductor insulation and outer liner made of special PVC
Usage in potentially explosive areas with ignition protection type
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Line group 3 (LG3) power cable
NYY Grounding cable 0.6/1 kV, power and control cable
Cu-conductor, bare, single or multiple wire
Conductor insulation and outer liner on PVC-basis
HO7RNF Heavy rubber hose
Cu-conductor, bare, finely stranded
Conductor insulation made of rubber, outer liner made of polychloroprene
HELUTHERM 145 Temperature-stable, non-halogen single conductor
Cu-stranded conductor, tin-plated
Conductor insulation made of polyolefin-copolymer, electronic beam cross-linked
and non-halogen
MEGAFLEX 500 Oil-resistant control line
sistant
ymer
Usage, e.g. in exterior area (cooler)
NOTE: The selection of the medium-voltage cable must be based on intended purpose and environmental
conditions. When used on the generator, the CU-stranded conductors must be bare and compacted as per
DIN EN 60228, Class 5.
Line group 4 (LG4) power cable
XFLEX-MONO Medium-voltage cable 20/12 kV, 10/6 kV
Manufacturer: Leoni CU-stranded conductor, bare, compacted as per DIN EN 60228, Class 5
Studer AG Conductor screen / dielectric cross-linked / insulation screen: extruded in a sin-
gle operation, boundary surface welded
Semiconductor swelling tape: Padded tape semiconductive, longitudinally water-
tight
Copper wire screen with exterior short-circuit band
Protective jacket: Polyetherurethane (PUR), black with red longitudinal stripes
XFLEXE-MONO Medium-voltage cable 20/12 kV, 10/6 kV without heat conduction
Manufacturer: Leoni CU-stranded conductor, bare, compacted as per DIN EN 60228, Class 5
Studer AG Conductor screen / dielectric cross-linked / insulation screen: extruded in a sin-
gle operation, boundary surface welded
Semiconductor swelling tape: Padded tape semiconductive, longitudinally water-
tight
Copper wire screen with exterior short-circuit band
Protective jacket: Polyolefin-copolymer, black with red longitudinal stripes
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3.5.8.5 Generator cabling
Generator connection
The generator terminal box contains the three connection points for the phases and also an option for con-
necting the neutral point and the housing.
Whether N and PE or PEN can be connected at the generator neutral point depends on the on-site plant con-
figuration. Ensure that the locally applicable protective measures are implemented.
The housing of the generator is connected with the flexible copper bridges on the vibration dampers to the
engine frame.
Generator cabling - cross-sections

The cross-sections for the generator cabling, if included in the scope of delivery, are configured by MTU On-
site Energy. The recommended data can be obtained from the cable list.
As with the other lines and cables, the company performing the work must also take the local situation into
consideration.
In general, highly flexible cables made of copper should be connected to the generator. Due to the constant
movement, rigid cables made of aluminum would be too strongly stressed and could be damaged.
To receive the degree of protection of the generator terminal box, cable glands should be used for cable en-
try.
If a rail system if used for generator cabling, flexible connectors must be used at the entry point to the gener-
ator terminal box. Appropriate sealing of the conductor rail entry is necessary. The design must guarantee
the contact protection and the required degree of protection.
Generator cabling - installation work

Cables installed on cable trays etc. must be bundled, sufficiently fastened and relieved of tension. This ap-
plies in particular to the generator power cables. Bundling reduces heating of the cables that occurs in non-
bundled systems due to eddy currents.
Extreme forces can be created in the event of a short circuit. Bundle the generator power cables, as shown
in the following illustrations, to minimize these forces.
The illustrations are extracts from DIN VDE 0298-4.
Description Arrangement
Special arrangement of 6 parallel single con-
ductors on one plane

ductors on top of one another
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ductors in a triangle

ductors on one plane
152 | Cabling | E 2015-08

Description Arrangement
ductors on top of one another

ductors in a triangle
Special arrangement of 12 parallel single

conductors on one plane

conductors on top of one another

conductors in a triangle
Generator cabling - cable entry

Cable entries must have a sufficient stress-relieving function. Use metric screw connections that can be in-
serted in the aluminum plates provided. Only one cable must be led in per screw connection. The respective
degree of protection of the device to be connected must be observed.
The screw connections at the generator must be suitable for the power cables used. A second generator
cable strain relief device (decoupled from generator / genset frame) serves to absorb the mechanical move-
ments of the generator (cable loop). Take the minimum bending radii into consideration.
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E 2015-08 | Cabling | 153

Figure 37: Generator cabling - cable entry
1 Generator 3 Metric screw connection 5 Cable strain relief
2 Generator terminal box 4 Cable loop
Generator cabling in the generator terminal box

When connecting the power cables to the copper rails in the generator terminal box, ensure that unnecessa-
ry loops are avoided. Install power cables, taking the minimum bending radius into consideration and using
the shortest possible route, from the screw connection to the clamping point. Avoid contact with cable
sheaths of the single conductors to prevent chafing when the machine is running. If contact between the
single conductors can not be avoided for space reasons, secure them to one another using cable clamps to
prevent chafing.
In all circumstances, prevent contact between power cables and the control cables located in the generator.
Secure power cables several times to prevent chafing of the cable sheaths due to generator vibration.
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3.5.8.6 Cable routing
The routing of electrical lines is regulated in DIN VDE 0100-520.
The installation should minimize the effects of external influences on the cabling system. For this purpose,
lines are routed in duct systems, cable carrying systems, tubes/pipes or inside walls. Protected lines are
used and the lines are fastened by clamps.
Unprotected installation of lines is permissible in the area of the raised floor and cavity floor provided that
the mechanical loads do not exceed the limit values of the cables.
Cables and lines must also be protected at the ends against the penetration of moisture.
Thermal stress
High ambient temperatures and heating due to electric load result in thermal stress on the cables and lines.
They must be protected against operational overloading and short circuits by overcurrent protective devices.
Overload protection consists of providing devices that interrupt the overload currents in the conductors of an
electric circuit before they can have a damaging effect on the conductor insulation, the connection points
and junctions and the surrounding area of the lines and cables.
According to DIN VDE 0100-430, the following conditions must be met to provide overload protection:
• IB ≤ In ≤ IZ
• I2 ≤ 1.45 IZ
IB: expected operating current of electric circuit
IZ: current carrying capacity of line of cable
In : rated current of protective device (note: with adjustable protective devices, In corresponds to the setting
value)
I2: Current that results in tripping of the protective device under the conditions defined in the device specifi-
cations.
Mechanical stress
The mechanical loads include the tensile load during installation and during a possible subsequent alteration
to the electrical installation. Also included are the bending radii and fastening of lines by clips, cable clamps
and strain relief devices.
According to DIN VDE 0298-3, the tensile load on electrical conductors for permanent installation must not
exceed 50 N/mm² (conductor cross-section) during routing. Excessive tensile forces result in a reduction in
cross-section, which results in an increased current density and thus heating of the conductors and prema-
ture aging of the insulation.
The permissible bending radii can be obtained from the respective manufacturer's documentation for the ca-
bles and lines used. If the permissible bending radii are undershot, material is buckled or stretched and the
electrical properties are thus altered. The permissible installation temperatures for the cables and lines used
can be obtained from the respective manufacturer's documentation and must be observed.
When clips, cable clamps and strain relief devices are used for fastening, ensure that the electrical properties
of the cables and lines are not impaired. If cables or lines are fastened with clips and routed horizontally on
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walls or ceilings, the following guide value applies to the spacing between the clips:
For nonreinforced cables and lines, 20x outside diameter.
This distance also applies to contact points when routing on cable trays and racks. For vertical installation,
the distances can be increased depending on the type of cable or clip.
When installing single conductors, the effects of short-circuit currents on the fastening must also be taken
into consideration. It is advisable to check the fastening after short circuits and at regular intervals.
E 2015-08 | Cabling | 155

External influences
The cable and line types must be selected and installed such that they can withstand all expected external
influences: presence of water, oil, other material influences, radiation (UV) and the influence of animals (e.g.
rodents) and plants (e.g. roots, mildew).
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156 | Cabling | E 2015-08

3.5.8.7 Battery connection
Batteries for diesel gensets are usually secured to the baseframe. However, they can also be installed exter-
nally in special cases.
All cables and connection must be clean and in good condition. A faulty or contaminated connection can
impair the transfer of electrical energy within the entire electrical system.
The wiring is determined by certain characteristics:
• System voltage
• Starter type
• Batteries used
• Location
These characteristics give rise to definitions for correct routing, the correct cable lengths and conductor
cross sections, terminals, cable clamps as well as requirements on cable sheaths, protective trunking and
connections.
The following guidelines apply to new installations:
• Complete copper cabling is recommended for all installations, because this has the lowest resistance and
is the least susceptible to faults.
• Attention must be paid to correct cable routing (not too tight or too loose), correct support as well as
avoiding excessive heat, abrasion and vibration.
• The wiring must be protected by cable ducts or sheathing if extreme heat and abrasion can not be avoid-
ed.
• Use pressure die-cast terminals made from a lead alloy for batteries with terminals.
• Use sealed terminals if sealed terminal blocks are available.
• Use ring terminals for all connections, with the exception of the battery connections.
• The frame must have its paint removed at the point where a ground connection is made, in order to en-
sure perfectly conductive connections.
• Coat connections with a corrosion inhibitor.
• Battery cable connections to the frame must have flat, hardened steel washers and a locknut.
Battery connection
The gensets are equipped with two or four 12 volt batteries in series connection (depending on engine type).
The batteries are accommodated in a steel baseframe in the direct vicinity of the genset, and are connected
in series using the supplied connection set. The batteries can be set up at the front end ahead of the genera-
tor. The openings for measuring the battery acid must be accessible (set up the frames next to one another if
necessary).
Please make sure when setting up that the plug connectors/terminal plugs are attached to the steel frame.
The illustration below shows four 12 V batteries in a series connection by way of example.
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E 2015-08 | Cabling | 157

Figure 38: Battery connection
1 Charging cable positive ter- 3 Connection to the starter 5 Connection to the starter
minal (positive terminal) (negative terminal)
2 Power cable 4 Starter battery 6 Charging cable negative ter-
minal
The power cabling between the battery and starters must be provided by the client.
Two positive and negative terminal clamps with stud bolt and corresponding cover cap are included in the
scope of delivery for connecting each of the power cables to the battery.
A non-binding suggestion for starter cabling can be seen in the wiring diagram below.
Figure 39: Battery circuit diagram

On engines with two starters, ensure that the power cables to both starters are identical.
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158 | Cabling | E 2015-08

3.5.8.8 Installation for intrinsically safe circuits
If the installation includes sensors (e.g. gas pressure monitor) that are in Ex-zones, special measures must be
introduced. Sensors for linking with cogeneration power plants are usually only installed in Ex-zone 2; in ex-
ceptional cases, also in Ex-zone 1.
Separating barriers for analog and digital signals are installed for this purpose. When configuring and defining
the components, the exact technical specifications of the sensors used in the Ex-zone must be known in ad-
vance.
For this reason, separating barriers are only installed in the MTU switch cabinets if the associated sensors
are also procured from MTU Onsite Energy. In this case, validation of the fail-safe feature as per DIN EN
60079-14 is carried out by MTU Onsite Energy and can be requested from MTU Onsite Energy.
If the sensor is not to be procured from MTU Onsite Energy, the customer must select and install the sepa-
rating barriers that match the sensor to provide validation of the fail-safe feature as per DIN EN 60079-14.
When wiring the intrinsically safe circuit, it has proved practical to use cables with a blue jacket (OZ-BL, OZ-
BL-CY). Although this is not prescribed, the advantage over all other forms of labeling is that the complete
cable is identified and not only the cable ends are marked.
The cable glands must also be blue.
Inside the switch cabinet, the cable jacketing should be stripped shortly before the separating barriers - out-
side the wiring duct. This means that the intrinsically safe circuit is marked even though the cable is routed
inside the normal cabling ducts.
It is therefore not necessary to install separate cabling ducts for the intrinsically safe circuits. Similarly, addi-
tional terminal blocks are no longer necessary for the intrinsically safe circuit because the cable strands can
be clamped directly at the separating barriers or isolator switch amplifiers.
On screened cables, the screen is only grounded on one side in contrast to general recommendations.
Grounding is installed outside the potentially explosive area.
The following illustration is an example of an Ex-barrier wired from above with a short shouldered jacket.
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Figure 40: Ex-barrier

1 Ex-barrier
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3.5.8.9 Electromagnetic compatibility – EMC
The term electromagnetic compatibility refers to known phenomena such as radio interference, mains pollu-
tion, overvoltages, electromagnetic interference, stray pick-up, etc.
To ensure trouble-free plant operation, the subject of EMC must always be included in planning
Basic rules of line installation
• Signal, control and data lines should not be interrupted.
• For disconnection points of screened lines, ensure that the screen connection is continuous.
• Lines must be installed on metallic, grounded cable bearers or ducts.
• Signal and power lines that are running parallel must be separated by a suitably large distance or with the
help of a grounded screening shield.
• The individual components of the cable bearing systems must have large-area connections with one an-
other and good electrical conductivity.
• Unscreened lines of the same electric circuit (supply and return conductors) must be twisted if possible,
or the distance between supply and return conductors must be kept as small as possible.
• Signal lines and associated voltage equipotential bonding cables must be installed the shortest possible
distance apart.
• Signal lines must not be routed past devices with strong magnetic fields (e.g. motors, transformers).
• Avoid unnecessarily long lines, including reserve lines.
• Provide interior and exterior lightning protection and grounding measures in accordance with the applica-
ble standards.
Lines
• The engine lines must be screened, low-capacitance, 4-wired cables.
• Install the engine line and the PTC/KTY line separated from one another. The PTC/KTY line must be con-
nected to the converter by a separate cable. From the perspective of EMC, PTC/KTY lines are treated as
control lines.
• The use of screened signal/data lines minimizes the parasitic induction.
Screens
• As far as the screening effect is concerned, braided screens are better than foil screens by a factor of five.
• Screens must have large-area contact for grounding and be highly conductive, or should be connected
with full surface conductive contact to the grounded housings. This is the only way that they are also ef-
fective against electromagnetic interference. Exception to this are cables in potentially explosive areas,
which are only grounded on one side.
• Cable screens should be placed directly after entry of the line in the cabinet on a screen busbar and rout-
ed further from there.
• Do not interrupt the screens
• The preferred way of fastening the screen braids is by means of metal cable clamps. The clamps must
enclose the screen over a large area and have good contact.
• At the plug connections of screened lines, only use metallic or metalized connector housings.
Refer to the respective circuit diagram to determine whether the line screen should be applied on one or two
sides. If one side is not applied, it must be fitted with insulation.
Always apply ON ONE SIDE:
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• For cables in potentially explosives areas, apply line screen in area that is not potentially explosive.
• Bus lines that connect several buildings or building parts with one another.
Always apply ON TWO SIDES:
• X2X cable
• Motors driven via a frequency converter.
Frequency converter
If frequency converters are used for operation of variable-speed auxiliary drives (pumps, fans, etc.), observe
the documentation of the manufacturer (e.g. SIEMENS: Micromaster, EMC installation directive) to ensure an
EMC-compatible layout.
160 | Cabling | E 2015-08

Provide a suitable screen contact at the motor connection. Metal cable glands can be used for this, which
enclose the screen 360° all round. Alternatively, a suitable screen terminal can be used in the motor termi-
nal box that also completely encloses the screen.
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3.5.8.10 Equipotential bonding, protective conductor and grounding
For the selection and installation of electrical equipment, grounding arrangements and protective conduc-
tors, see DIN VDE 0100-540.
As the design of the equipotential bonding and the protective conductor depends on the form of the local
power grid, it is not possible to provide details at this point. Only generally applicable information independ-
ent of the form of power grid can be provided at this point.
Equipotential bonding
Apart from the module frame and heat module frame, all other metallic, electrically conductive components
must be included in the local equipotential bonding. This includes, e.g. heating water pipes, gas line, exhaust
system, cable trays, etc.
Several connection points for equipotential bonding have already been prepared at the module frame. A steel
strip embedded in the foundation can be very easily connected at one of these positions. The equipotential
bonding is implemented from the module frame to the generator frame via flexible connecting lines.
Protective conductor
The protective conductor must be connected in every case to the housing of the generator. Grounding of the
generator neutral point depends on plant-specific factors.
The local specifications of the power supply company or the safety regulations must be observed to ensure
that grounding is carried out correctly.
Central grounding point

State of the art is the version with a central grounding point. This reliably prevents stray currents.
If a central grounding point is used, there is only one connection between PEN and ground. The complete run
of the PEN conductor must be insulated.
For networks with decentralized power supply, a further central ground point is possible. The two areas with
central grounding points must not be operated in parallel.
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3.5.8.11 Cabling – Check and testing
The equipment operator must ensure that electrical installations and operating equipment is inspected for
proper condition by an electrician or under the management and supervision of an electrician.
This should take place prior to commissioning and after an alteration or repair before putting the equipment
back into operation.
Check intervals should be calculated such that any defects that are likely to occur are recognized in good
time.
It can generally be assumed that permanently installed cables and lines have a longer working life and longer
inspection intervals.
Shorter intervals are recommended in the case of cables and lines used at the limits of the permissible
range. This applies in particular to:
• Minimum bending radius
• Radiation (e.g. sunlight)
• Tensile loads
• With the influence of surrounding chemical substances and unconfirmed stability
• With water accumulation or condensation in the area of the connection points
Cables and lines should be visually inspected for changes in appearance at the latest if there are grounds for
believing that the equipment has been subject to extraordinary overloads (electrical, thermal, mechanical,
chemical).
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3.6 Transport
3.6.1 Transporting, lifting and storing
Due to the large number of possibilities for installing the engine-generator set, this section can only provide
general information. Installation of the engine-generator set depends on location factors and applicable laws,
ordinances and/or regulations that vary from place to place and from country to country. Furthermore, there
may be differences between the individual gensets. Please obtain the respective details on transport, lifting
and storage of the gensets from the installation and commissioning instructions.
During transport of the engine-generator set, the owner is responsible for ensuring the following:
• An unobstructed route is available for the engine-generator set during transport, and there is a suitable
location for it.
• Suitable equipment is available and is used for transporting the engine-generator set.
• Forklift drivers and crane operators are certified.
• Lifting and handling of heavy objects are carried out or supervised by people who are familiar with lifting
procedures.
• Suitable equipment is provided for lifting the engine-generator set, and is maintained.
• The corresponding procedural instructions of the manufacturer are followed when lifting and handling the
engine-generator set.
Lifting
The attachment points on the engine and generator are only configured for their individual load. They must
not be used when lifting the complete engine-generator set. Always use the correct lifting equipment when
lifting heavy parts.
The engine-generator set is only allowed to be lifted at the attachment points provided for this purpose. Re-
fer to the layout and planning drawings to find the dimensional is for lifting the genset .
A sticker on the genset contains information on lifting eyes, center of gravity and tilt safety device.
Transportation
The engine-generator set is only allowed to be transported in its installation orientation. Maximum permissi-
ble diagonal pull is 10°.
The genset must be safely secured to prevent it from tipping over during transport. Cover the engine-genera-
tor set with a tarpaulin if necessary, to protect it against influences of the weather.
On slopes and ramps, always make sure that the engine-generator set is secured to prevent it from sliding
and tipping over.
Before transporting the genset, the crankshaft transport locking device and the engine mounting locking de-
vice must be installed.
Depositing the genset

Place the genset on a firm, flat surface only. Make sure that the consistency and load-bearing capacity of the
ground or support surface is adequate.
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Never set down engines onto the oil pan unless expressly permitted by MTU Onsite Energy on an engine-
specific base.
Storage
The genset must have a suitable preservation agent applied to it for storage. For more details about this,
refer to the regulations on preservation and re-preservation issued by MTU Onsite Energy (A001071/...).
Install or store the genset in a dry, frost-free (> 5 °C) room and cover with a tarpaulin. In case of special
packaging, take care not to damage the aluminum foil and check the moisture indicator on a regular basis
(Control specifications for MTU special packaging).
164 | Transport | E 2015-08

3.7 Validation and Commissioning
3.7.1 Validation and commissioning
Before initial operation
• The engine-generator set must successfully pass a commissioning inspection.
• The engine-generator set must be reliably grounded according to the requirements of national, state or
local regulations.
• All maintenance and repair work must be completed.
• All loose components must be removed from the genset.
• The genset must be unlocked by the same person who put it in the blocked and locked status.
• No people and no loose components are allowed to be in the immediate vicinity when the genset is taken
into operation.
Immediately after commissioning of the genset, a functional check must be carried out to ensure that all
monitoring and display instruments as well as the signal transmission and alarm system are working correct-
ly.
Validation and commissioning – gas genset

Forms are available on the MTU Business Portal which specify the process of validating and commissioning a
cogeneration power plant from MTU Onsite Energy:
• "Notification of commissioning readiness" for all cogeneration power plants from MTU Onsite Energy
• "Pre-commissioning checklist G4000 series" for 4000 series
• "Pre-commissioning protocol" for 400 series
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166 | | E 2015-08
4 Drawings
4.1 Gas genset - planning drawing ............................................................................................................................................................... 169
E 2015-08 | Drawings | 167

168 | Drawings | E 2015-08
4.1 Gas genset - planning drawing
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288 | | ##Druckschriftnummer##D 2015-##
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170 | Drawings | E 2015-08
6.2 Gasaggregat - Planungszeichnung
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##Druckschriftnummer##D 2015-## | | 289
E 2015-08 | Drawings | 171

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172 | Drawings | E 2015-08
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178 | Drawings | E 2015-08
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180 | Drawings | E 2015-08
5 Diagrams
5.1 One-line diagram - gas genset (MMC4000) ......................................................................................................................................... 183
5.2 One-line diagram - gas genset (MIP4000) ........................................................................................................................................... 185
5.3 One-line diagram - gas genset (KWK400) ........................................................................................................................................... 187
E 2015-08 | Diagrams | 181

182 | Diagrams | E 2015-08
5.1 One-line diagram - gas genset (MMC4000)
1 2 3 4 5 6 7 8
Gebrauch und Vervielfältigung nur mit ausdrücklicher Genehmigung zulässig! Versorgung 400VAC Versorgung Versorgung
Schwarzstart 400VAC 400VAC
Hilfsantriebe MTU-Interface-Panel MMC intern
von Sammelschiene
Versorgung 400VAC Einspeisung Versorgung

A Schwarzstart 400VAC 400VAC A
Hilfsantriebe MMC intern
von Generator
-1F1 -1F2 -2F1 -2F2 -2F3 -2F4

NH00 NH00 NH00 D02 NH00 NH00 -174Q1 -267Q1 -275F1 -286Q1
__A __A __A 25A __A __A
gG/gL gG/gL gG/gL gG/gL gG/gL
B B
-1K1 -1K2
Gasverdichter Frischöl
Pumpe
Notkühler Gasfackel
Pumpe
C C
-3F1 -4F1 -4F2 -4F3 -4F4 -5Q1 -79Q1 -113Q1 -124Q1 -125Q1 -134Q1
Versorgung 400VAC Versorgung

Schwarzstart 400VAC
Hilfsantriebe
von Generator
Beleuchtung bauseitige bauseitige Ladegerät Heizwasser Gemisch

Belüftung Verwendung Verwendung Anlasser-Batterie Pumpe Kühlwasser
Die Zeichnung ist Eigentum der MTU onsite energy GmbH.
D Schaltschrank Steuer- bauseitige Ladegerät Motor Heizwasser Pumpe

D
-113Q1 -124Q1 -125Q1 -134Q1 trafo Verwendung Steuerbatterie Kühlwasser Doppel-Pumpe
24VAC Pumpe
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Heizwasser Gemisch
Pumpe Kühlwasser
Motor Heizwasser Pumpe
E Kühlwasser Doppel-Pumpe
E
Pumpe
HINWEIS:
Einstrichschema an
Anlagenkonfiguration
anpassen.
F Datum 20.01.14 Projekt: Beschreibung: Anlage: =

Bearb. Th. Asam Standard mit Optionen MTU Module Control Baureihe 4000 Ort: + Folge: 2
Geprüft - - - -AxxxxV4000L6xx- Übersichtsplan Datei: Uebersicht 1 von 2
Materialnummer: Kommission: -22xxx-xxxx- Version: V3.3.4.0 Status: - zum Schaltschrankbauer - Gesamtseite: 14 von 364
1 2 3 4 5 6 7 8
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184 | Diagrams | E 2015-08
5.2 One-line diagram - gas genset (MIP4000)
1 2 3 4 5 6 7 8
Gebrauch und Vervielfältigung nur mit ausdrücklicher Genehmigung zulässig!
Niederspannung
___ V
A A
EMM -12A1
Netzmessspannung ___V
NLS M
EIN-AUS-Befehl
Netzschutz
___ V Synchronisierung NLS
B B
Sammelschienen-Spannung ___V
GLS M
EIN-AUS-Befehl Synchronisierung GLS
Generator-Spannung ___V
Generator-Schutz
C C
-komplette Seite
Generator-Strom _A
-Option5a
D D
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+ Kunde
+ MTU OEG
E E
G
Mess-Wandler
Schutz-Wandler
____ kVA / ___ V
F Datum 10.12.13 Projekt: Beschreibung: Anlage: =BHKW

Bearb. Th. Asam MTU Interface Panel MIP MTU-Interface Panel Baureihe 4000 Ort: +MMC Folge: 3
Geprüft - - - -AxX XXV4000L6XX- Niederspannung Datei: Uebersicht 1 von 3
Materialnummer: Kommission: - 10.22xxx - Version: V3.4.0.0 Status: - zum Schaltschrankbauer - Gesamtseite: von
1 2 3 4 5 6 7 8
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186 | Diagrams | E 2015-08
5.3 One-line diagram - gas genset (KWK400)
1 2 3 4 5 6 7 8
A Gebrauch und Vervielfältigung nur mit ausdrücklicher Genehmigung zulässig! +TRAFO 3

A
-T1 HINWEIS:
Einstrichschema an
Anlagenkonfiguration
+NSHV
anpassen.
-F1NH 1
kuppelschalter
B B
Netz-
+NSHV M +NSHV
-Q1 -Q2
B 16A
-X2
2A
C C
Netzmessspannung
-2F1
D02
-1T1-3 25A
250/5A
-1Q1
D D
315 A
-9K2
132kW
265A
-1F1 -X2 -3F1 -4F1 -5F1 -5Q1 -69F1 -69Q1 -73Q1 -124Q1 -268Q1
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B 6A 2A B 10A C 2A B 6A 1,5A B 10A
E E
-1G1 G
Geno-Spannung Geno-Strom Sammelschienen- Beleuchtung Steuer Ladegerät Batterie Kühlwasser Kühlwasser Schallhauben Heizwasser Schmieröl
spannung Belüftung Spannungs 24 VDC Ladegerät Vorwärmung Pumpe Lüfter Pumpe Pumpe
Steckdose Trafo gesicherte
24 VAC Spannung
F Datum 30.09.13 Projekt: Beschreibung: Anlage: =

Bearb. Danhofer KWK V7.5.1.0 mit Optionen KWK Steuerung Ort: +MMC Folge:
Geprüft -ohne- ME3066D3 Einstrichschema Datei: Einstrichschema 1 von 1
Materialnummer: 1022xxxnnnn Kommission: 10.22___-___ Version: V7.5.1.0 Status:- Freigabe - Gesamtseite: 7 von 147
1 2 3 4 5 6 7 8
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6 Piping and Display Scheme
6.1 R&I-scheme - gas genset with 12V4000L32 engine ........................................................................................................................ 191
E 2015-08 | Piping and Display Scheme | 189

190 | Piping and Display Scheme | E 2015-08
6.1 R&I-scheme - gas genset with 12V4000L32 engine
AP001
AA001
AA001
AA001
Option Bauseitige
MTU Anlage
AA001
Option BP001
Bauseitige Bauseitige MTU
Option Option
Anlage Anlage MTU
MTU Bauseitige
Anlage
AA001
BB001
AA001
AT001
AA001
AC001
Bauseitige
Anlage
MTU Kunde
Option
MTU
Komponenten-
kennzeichnung
MSR-
Kennzeichnung
Die technischen Daten beziehen sich nur auf die von MTU
angebotenen Baugruppen. Im Schema angegebene
Alle Tiefpunkte und absperrbaren Anlagenteile mit Entleerung.
MTU Bauseitige
Anlage
Bauseitige MTU
Anlage
Bauseitige
Anlage
Option
MTU
MTU Bauseitige
Anlage
MRA10HA001 MRG10HB005 MRA10HB003 MRA10HA005

12V4000L32FB / GB1169B5 93251004171 Option 93251008315 Option 9326200 -8230/8226 Option
Baugruppe_Motor Baugruppe_Gasverdichter
Sachnummer nach Freigabeliste Leistung:140 kW Differenzdruck:160 mbar
Druckverlust:8 kPa Stellbereich:35 - 60Hz

Druckverlust_HT: 19,5 mWs ATEX_Innen:II 2G
Druckverlust_LT: 2,4 mWs FU Regelung mit Thermokontakt
AG_Massenstrom: 7021 kg/h
AG_Gegendruck: 30 - 60 mbar
MRA10HB001 MRG10HB006 MRA10HB002 MRA10HB004

93280146133 Grundlieferumfang 93251004171 Option 93263008017 Option 93251008337 Option
Baugruppe_Beipack_GB Baugruppe_Oxidationskatalysator_40mg Baugruppe_Verbindungsgruppe
NT-Kreis: Metallwellschlauch 2xDN65 Leistung:140 kW Nur bei Lieferumfang GR/GC
HT-Kreis: Gummikomp. 2xDN100 PN16 Druckverlust:8,7 mbar
Druckverlust:8 kPa Flansch:DN400 PN10
1xDN8 M16x1,5 Ermeto (-6143)
AG: Kompensator 1xDN250 PN6 Stufensteuerung / 6 Stufen inkl. Kombimessadapter
MRN10HA004 MRA01HA001 MRA10HA004 MRG31HC001

93262008215 Grundlieferumfang 93283006042 Option 93263008026 Option 93251008421 Option
Baugruppe_Gasregelstrecke
Nennweite: DN125 Flansch:DN400 PN10 Leistung:680 kW
Druckstufe: PN16 - BG NT Temperatur Regelgruppe
Druckverlust:15 mbar
- BG HW Anschluss
Restschalldruckpegel:60 dB(A) in 1m
Dimensionen Beipack GR gleich GB
MRG40HB009 MRA10HB004 MRA10HA002 MRA10HA006

TIM-ID: 0000086705 - 001
93251004198 Option 93251008316 Option 93251008398 Option 93263004103 Option

Baugruppe_HW_Anschluss
Leistung:700 kW Flansch:DN400 PN10
Max.ext.Differenzdruck: 8 mWs
Druckverlust:12,7 kPa Max.ext.Volumen: 500l Flansch:DN100 PN16 Druckverlust:12 mbar
FU Regelung mit Thermokontakt

Restschalldruckpegel:70 dB(A) in 1m
E 2015-08 | Piping and Display Scheme | 191

TIM-ID: 0000086705 - 001
192 | Piping and Display Scheme | E 2015-08
7 Appendix A
7.1 MTU contact persons/service partners
Our worldwide sales network with its subsidiaries, sales offices, representatives and customer service cen-
ters ensures fast and direct support on site and the high availability of our products.
Local support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the MTU Internet site: http://www.mtu-online.com
24h hotline
With our 24h hotline and the outstanding flexibility of our service staff, we are always ready to assist you –
either during operation, for preventive maintenance, corrective work in case of malfunction or changed oper-
ating conditions, or for spare parts supply.
Your contact person in our Customer Assistance Center:
E-mail: info@mtu-online.com
Tel.: +49 7541 9077777
Fax: +49 7541 9077778
Asia/Pacific: +65 6100 2688
North and Latin America: +1 248 560 8000
Spare parts service

Fast, simple and correct identification of spare parts for your drive system or vehicle fleet. The right spare
part at the right time at the right place.
With this aim in mind, we can call on a globally networked spares logistics system, a central warehouse at
headquarters and on-site stores at our subsidiary companies, agencies and service workshops.
Your contact at Headquarters:
E-mail: spare.parts@mtu-online.com
Tel.: +49 7541 908555
Fax: +49 7541 908121
TIM-ID: 0000000873 - 015
E 2015-08 | Appendix A | 193

8 Appendix B
8.1 Index
A Controller
Acoustic data 48 – Gas genset 105
Aeration and ventilation system – Module Interface Panel (MIP) 105
– Gas genset 120 – MTU Control System (MCS) 105
– Ventilation 120 – MTU Module Control (MMC) 105
Air filter 92 Coolant pipework 142
Air pipelines 125 Coolant preheating 99
Ambient conditions 65 Cooling load 33
Apparent power 28 Cooling system 141, 142
Application groups – Gas genset 97
– Gas genset 34 Current load type
Assembly instructions 111 – Base load 55
– Medium load 55
B – Peak load 55
Base load requirement
D
– Thermal 39
Battery 102 Degrees of protection 85
Battery charger 104 Differential pressure
Battery connection 157 – Calculation 93
– Indicator 93
C Dimensioning
Cable list 147 – Gas genset 76
Cable routing 155 Documents
Cabling 144 – Gas gensets 23
– Cable routing 155
E
– Check and testing of cabling 163
– Electromagnetic compatibility 160 Effective power output 28
– Equipotential bonding, protective conductor and Electrical connections 144
grounding 162 – Battery 157
– Generator cabling 152 Electrical power
– Installation for intrinsically safe circuits 159 – Key planning parameters 32
Catalytic converter 127 – Power properties
CE mark 17 – Gas genset 28
CH4 control 44 Electromagnetic compatibility 160
Check and testing of cabling 163 Emission 48
Cogeneration (CHP) 39 Engine coolant heat exchanger 100
Combustion air Engines
– Supply 122 – Gas genset 80
– Volume 122 Engine-generator set 71
Company presentation 7 Equipotential bonding 162
DCL-ID: 0000037142 - 002
Compartment air Excitation systems 84

– Compartment air supply 123 Exhaust flue 136
– Compartment air volume 123 Exhaust gas heat exchanger 135
Configuration Exhaust pipe 133
– Cooling system 141 Exhaust pipe bellows 129
Configuration planning 16 Exhaust silencer 134
Conformity 17 Exhaust system
Contact persons 193 – Configuration 128
Control – Gas genset 94
– Control versions – Gas genset 108 – Requirements 127
Control versions 108 Exhaust values 48
194 | Appendix B | E 2015-08

Expansion tank 142 K
Key planning parameters
F
– Electrical power 32
Fan cooler 101
Foreword L
– this manual 5 Line groups 149
Fresh oil filling 138 Load management
Fuel – Gas genset 56
– Gas 64 Load profile 56
Fuel supply system Load properties 50, 59
– Gas genset 119 Load special features 50
Fuel system Load stages 56
– Gas genset 87 Load types
– Gas mixer 89 – Linear loads 50
– Gas train 88 – Non-linear loads 50
– Installation of the gas system 90 Lube oil cooler 95
Lube oil filter 95
G
Lube oil system
Gas – Gas genset 95
– Requirements 64
Gas genset M
– Dimensioning 76 Machinery Directive 17
Gas mixer 89 Mains operating modes 37
Gas operating modes 44 Mains operation 37
Gas operation 44 MTU contact persons 193
Gas train 88 Multi-gas operation 44
General conditions
– Gas genset 25 N
Generator 81 Noise 48
– Degrees of protection 85
– Excitation systems 84 O
Generator cabling 152 Objective power requirement 32
Generator efficiency 28 Oil level monitoring 95
Genset line 65, 68 Oil line 137
Genset power Oil priming 95
– Gas gensets 69 Oil quality 138
Grid parallel operation 37 Oil replenishment device 139
Grounding 144, 162 Oil – Change 138
One-line diagram 75
H
Operating mode
Heat demand 59 – Cold 43
Heat sink 59 – Heat 43
Hotline 193 – Thermal 39
HP spec Operating modes 18
– Rating program 68 – Gas 44
HP-Spec 22 – Mains 37
Operational limits
I
DCL-ID: 0000037142 - 002
– Gas gensets 47

Influencing factors on power
– Diesel genset 65 P
Installation for intrinsically safe circuits 159 P&I diagram 79
Installation of the gas system 90 P&ID 79
Intake air system Peak load boiler 39
– Gas genset 91 Peak load requirement
Interruption time 25, 32 – Thermal 39
IPAS 21 Performance class 25
IPAS application engineering tool 21 Pipeline and instrumentation diagram 79
Isolated operation 37 Plate-core heat exchanger 100
Isolated parallel operation 37
E 2015-08 | Index | 195

Power Test conditions
– Engine-generator set 68 – For engines 15
Power calculation 57, 62 – For gensets 15
Power factor (cos φ) 28 Test stand 15
Power properties Thermal capacity 33
– Cold 33 Thermal operating modes 39
– Electrical power Thermal output 33
– Gas genset 28 Transporting, lifting and storing 164
– Heat 33 Trigeneration (combined cooling, heat and power, CCHP)
– Thermal power 33 43
Power ranges
– Gas gensets 69 U
Power reduction 65 UL test mark 17
Preheater 99 Used oil change 138
Product portfolio 10
Product safety 17 V
Protective conductor 162 Validation 165
Putting into operation 165 Ventilation
– Gas genset 120
Q
Qualitative requirements W
– Diesel genset 20 Wiring
– Gas genset 20 – Cable list 147
– Line groups 149
R – Standards and guidelines 145
Rated power 32
Rating tool 22
Reactive power 28
Referenced documents
– Gas gensets 23
Referenced standards
– Gas gensets 23
S
Service partners 193
Simultaneity factor 32
Single gas operation 44
Spare parts service 193
Standards
– Gas gensets 23
Standby power operation 37
Starter
– electric 102
Starter battery 103
Starter system
– Gas genset 102
Supply and exhaust air system
DCL-ID: 0000037142 - 002
– Air pipelines 125

– Combustion air 122
– Compartment air 123
Switchover time 25, 32
Switch-on power 25
System business 13
T
Target group 5
Temperature difference 33
196 | Index | E 2015-08

Installation Guideline Gas ENU

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Application Guidebook

Application and installation guidelines

3.5.3 Fuel supply system – Gas genset 119

E 2015-08 | Table of Contents | 3

DCL-ID: 0000037142 - 002

4 | Table of Contents | E 2015-08

Structure of the manual

E 2015-08 | General Information | 5

TIM-ID: 0000057260 - 002

6 | General Information | E 2015-08

Figure 1: Portfolio of Rolls-Royce Power Systems AG

MTU Onsite Energy

E 2015-08 | General Information | 7

Key technologies and expertise

8 | General Information | E 2015-08

Gas gensets and cogeneration power plants

Figure 4: Gas gensets and cogeneration power plants

E 2015-08 | General Information | 9

Figure 5: Systems for power and/or heat generation

10 | General Information | E 2015-08

Power modules (diesel genset)

Mobile power modules

280 kWe 550 kWe

Stationary power modules

E 2015-08 | General Information | 11

Stationary power modules (gas gensets)

Cogeneration power plants

TIM-ID: 0000052690 - 002

12 | General Information | E 2015-08

Figure 6: System business units

Series system business (SSB)

Customer-specific system business (CSB)

• Gas gensets (stand-alone)

E 2015-08 | General Information | 13

Project-specific system business (PSB)

14 | General Information | E 2015-08

Standard end-of-line test for MTU Onsite Energy gensets

Table 1: Extract from route card

Customized Factory Acceptance Test

E 2015-08 | General Information | 15

Request for quotation

Order receipt and production

Integration and commissioning

16 | General Information | E 2015-08

Integration of machines / pressure vessels / gas appliances in a complete plant

E 2015-08 | General Information | 17

Cogeneration power plants

18 | Basic Knowledge | E 2015-08

Pure electricity generation

E 2015-08 | Basic Knowledge | 19

Typical voltage deviation on load G2 = -20% G1 = -25%

20 | Basic Knowledge | E 2015-08

IPAS basic data

E 2015-08 | Basic Knowledge | 21

TIM-ID: 0000060577 - 001

22 | Basic Knowledge | E 2015-08

Referenced standards and directives

E 2015-08 | Application engineering for gas gensets | 23