PRODUCT PRESENTATION SERIES 4000 1500 – 3400 kVA

© MTU Onsite Energy Systems GmbHAll rights reserved

PRODUCT PRESENTATION

SERIES 4000

1500 – 3400 kVA


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Page 2 / MTU Onsite Energy Systems GmbH / 12/16/2013

© MTU Onsite Energy Systems GmbH / All rights reserved

TODAY‘S AGENDA

01. Philosophy02. Product Family Concept03. Product Overview04. Diesel Generator Set Ratings05. Main Components06. Peripheral Components07. Summary





01PHILOSOPHYMTU ONSITE ENERGY SERIES 4000 GENSETS





PHILOSOPHY.

Our job: Providing reliable power for all customer applications under

all environmental conditions

Vision: We at Tognum set the standard as the preferred partner for the best

solutions in power and propulsion.

Strategy: Maintaining leadership in product innovation. Broadening application

and customer portfolio. Custom-made products. Integrating system

and service offerings.

Just like MTU engines, our gensets are: proven reliability exceptionally economical have outstanding load acceptance

characteristics have outstanding load factors in all

application groups designed for easy maintenance




02Product Family Concept





PRODUCT FAMILY CONCEPT.TARGET.

Harmonization of our product design across all global MTU OnsiteEnergy locations

Harmonization of our product design across all MTU Onsite Energyproduct series

Harmonization of our product design to our customers requirements




PRODUCT FAMILY CONCEPT.ACHIEVEMENTS.

Significant enhancement of standard options

Improved system integration ability

Improved overall product quality

Easier customization of the genset




03PRODUCT OVERVIEW





PRODUCT OVERVIEW.STANDARD SCOPE OF SUPPLY.

Optimization

Fuel consumption optimized

TA-Luft optimized

NEA optimized

Generator

Marathon generator Winding RTDs

Base Frame

Welded design

Resilient engine and generator mounting

Control Panel

Control variant 1+ (cabinet without controller)

Air Intake

Standard dry air filter

Fuel System

Fuel main filter

Starting / Charging

Electric starter (24 VDC / 2x 9kW)

Voltages

400V




PRODUCT OVERVIEW.STANDARD SCOPE OF SUPPLY.

Certification / Standards

Engine-generator set

engine-generator set standard factoryacceptance testing

Applicable Performance class G3

BS-4999

VDE 0530

ISO 8528

NFPA 110

Generator

IEC 60034-1

NEMA MG 1-22

Radio interference level N

Engine

DIN ISO 3046

SAEJ 1995 / J1349

Technical Documentation

Operation and Maintenance Manual

Product information (functionaldescription)

Operation, troubleshooting andmaintenance instructions

Tools list

Fluids and Lubricants Specification

Quick Reference Guide




PRODUCT OVERVIEW.OPTIONAL SCOPE OF SUPPLY.

Voltages

380V, 415V

11kV

Generator

Oversized Marathon generator

Medium voltage Marathon generator

Leroy Somer generator (low & medium voltage)

Bearing temperature sensor

Anti condensation heaters (Standard for MV)

Differential protection CT’s

Starting / Charging

Starter battery

Battery rack Battery charger (battery charging alternator is

no longer part of our scope of supply)

Cooling System

Mechanical radiator (40°C & 50°C*)

Electrical driven radiator (40°C & 50°C)

Piping between engine and radiator incl.flexible hoses

Jacket water heater

Radiator front protection

Lubrication System

Lube oil extraction pump

* 50°C mechanical driven radiator is not available for genset models with 20V4000G63L engine





Fuel System

Fuel pre filter

Fuel pre filter with water separator and water level sensor

Fuel pre filter switchable with water separator and water levelsensor

Fuel return cooler integrated into radiator

Fuel return cooler (loose delivery)

Exhaust System

SilencerSilencer foruse w/oY-pipe

Silencer foruse withY-pipe

10 dB(A) 12V, 16V models -

30 dB(A) 12V, 16V models All models

40 dB(A) 12V, 16V models 20V models

Y-pipe

Exhaust bellows with connecting flange

Air Intake

Heavy duty air filters





Control Panel

Basler controller

Deif controller

Island operation (Control Variant 2)

Automatic Mains Failure (AMF) operation to becombined with Automatic Transfer Switch (ATS)(Control Variant 3a)

Automatic Mains Failure (AMF) operation to becombined with electrical interlocked circuitbreakers (Control Variant 3b)

Island parallel operation (Control Variant 4)

Automatic Mains Failure (AMF) operation withmains restoration synchronization (ControlVariant 5)

Mains parallel operation of a single genset(Control Variant 6)

Mains parallel operation of multiple gensets(Control Variant 7)

Circuit Breaker

Manual operated circuit- breaker IEC 3/4pole

Electrical operated circuit- breaker IEC 3/4pole

Automatic transfer switch

Circuit breakers as stand-alone solution




04RATINGS





RATINGS.

POWER RATINGS DEFINITION OF MTU OE.

Power declaration for genset (ISO 8528-1) MTU Ratings

Emergency Standby Power (ESP)

Maximum power during a variable electrical powersequence

Operating hours per year: 200 Load factor: < 70%

Standby power (3D)

Operating hours per year: 500 Load factor: < 85%

Prime Power (PRP)

Maximum power which a generating set is capable ofdelivering continuously whilst supplying a variableelectrical load

Operating hours per year: unrestricted Load factor: < 70%

Prime power (3B)

Operating hours per year:unrestricted

Load factor: < 75%




RATING RANGE.3B.

Genset ModelEngine

3B Rating in kVA*

40°C / 400m (NEA: 40°C / 100m)

Fuel consumptionoptimized

TA-Luft optimized NEA optimized

DP1500D5S 12V 4000G23 1500 – 1550 1500 – 1550 1500 – 1550

DP1650D5S 12V 4000G23 1550 – 1650 1550 – 1650 1500 – 1650

DP1800D5S 12V 4000G63 1750 – 1850 1750 – 1850 1800 – 1850

DP2000D5S 16V 4000G23 2050 – 2100 2000 – 2100 2000 – 2100

DP2250D5S 16V 4000G63 2100 – 2300 2100 – 2300 2030 – 2250

DP2500D5S 20V 4000G23 2550 – 2600 2500 – 2600 2150 – 2250

DP2800D5S 20V 4000G63 2800 – 2900 2800 – 2900 2200 – 2300

DP3000D5S 20V 4000G63L 3000 – 3100 3000 – 3100 2250 – 2350

* Ratings refer to Marathon generators and different voltages from 380V to 11kV. Ratings range covers the radiator options(mechanical radiator and electrical driven radiator) and generator options (oversized, derating optimized and medium voltage.




RATING RANGE.3D.

Genset ModelEngine

3D Rating in kVA*

40°C / 400m (NEA: 40°C / 100m)

Fuel consumptionoptimized

TA-Luft optimized NEA optimized

DS1650D5S 12V 4000G23 1650 – 1700 - 1650 – 1700

DS1750D5S 12V 4000G23 1650 – 1850 - 1650 – 1800

DS2000D5S 12V 4000G63 1950 – 2050 - 1950 – 2000

DS2250D5S 16V 4000G23 2200 – 2350 - 2150 – 2300

DS2500D5S 16V 4000G63 2200 – 2600 - 2030 – 2250

DS2650D5S 20V 4000G23 2600 – 2900 - 2150 – 2400

DS3100D5S 20V 4000G63 3100 – 3150 - 2350 – 2500

DS3200D5S 20V 4000G63L 3100 – 3400 - 2500 – 2600

* Ratings refer to Marathon generators and different voltages from 380V to 11kV. Ratings range covers the radiator options(mechanical radiator and electrical driven radiator) and generator options (oversized, derating optimized and medium voltage.




05MAIN COMPONENTS





MTU SERIES 4000 ENGINE.TECHNICAL DATA.

MTU Series 4000 engine: Main technical data

Bore: 170 mm

Stroke: 210 mm

Displacement per cylinder: 4.77 l

Injection system: Common rail

Compression ratio: 16.5

Turbocharging: Single stage

Compression ratio: 16.5

Exhaust system: dry

Electronic:

ADEC (Advanced Diesel EngineController) Smart Connect

SAM (Service Application Module)

Cooling system: Separate dual-circuit cooling




MTU SERIES 4000 ENGINE.KEY BENEFITS.

Best in class Fuel Economy

High efficient common rail injection system

Injection pressure up to 1800 bar

MTU16V4000G23

CAT3516 BTA

CumminsQSK 60-G4

Perkins4016-61TRG2

PRP Rating [kWm] 1,798 1,755 1,730 1,774

Fuel consumption@ 100% load

[g/kWh]188 210 190 205

Fuel consumption@ 75% load

[g/kWh]191 208 187 206





Best in Class Transient Response

Frequency and voltage deviations according to performance class G3 as per

ISO 8528

100% load acceptance according to NFPA 110

Higher displacement of MTU engine lower turbo boost pressure necessary better transient performance

Load acceptance of MTU engine: >70% (depending on on-site engineconditions)

Load acceptance of competitor engines: regularly <70% (depending on on-siteengine conditions)





Proven Reliability

Low vibration characteristics less stress on engine and peripheral components

High reliability due to high displacement engine concept in comparison to competitors

lower mean effective pressure less stress on engine

Long time before overhaul (TBO): exceeding 30,000 hours in continuous applications

MTU16V4000G23

CAT3516 B TA

CumminsQSK 60-G4

Perkins4016-61TRG2

PRP Rating [kWm] 1,798 1,755 1,730 1,774

Cylinders 16 16 16 16

Displacement[liters]

76.27 69 60.36 61.12





Highest Load Factors

Prime Power 75% average load factor

Emergency Standby Power 85% average load factor

Higher load factors in comparison to competitors higher available power

MTU16V4000G23

CAT3516 B TA

Cummins QSK60-G4

PRP Rating [kWm] 1,798 1,755 1,730

PRP Load Factor 75% 70% 70%

Average availablepower [kWm]

1,349 1,229 1,211





Outstanding De-rating Behaviour

ADEC engine controller with Engine Site Condition Management System

(ESCM) Higher availability of power for each application and site condition

Full power up to 40°C and site altitude of 400m above sea level




GENERATORS.OVERVIEW.

General:

Main supplier: Marathon

Second supplier: Leroy Somer

Leroy Somer Generators will be integrated as “Release to Offer” (RtO)

Generators will be shown in price list

Generators can be configured in IPAS

Option is not 100% designed longer lead times

Voltage Marathon Leroy Somer

380V / 400V / 415V RtO

380V / 400V / 415VOversized

11kV RtO

- Standard Option

- Customized

RtO – Release to Offer




MARATHON GENERATOR.STANDARD FEATURES.

Low Voltage Alternator:

Single-bearing

Double bearing and rubber coupling for

gensets with 20V4000 engine

Damper cage/winding

Disc coupling

Brushless, self exiting, self regulating

PMG excitation

Digital voltage regulator

250% short circuit capability

Heavy duty shielded ball bearings (min. life

of 40,000 h), regreasable

Ingress Protection: IP23

Insulation class H

Anti-condensation heaters for


Winding temperature sensors*


High load acceptance and low

voltage dip

Standard

* In combination with Basler controller the analogue expansion module is required for the monitoring of the winding temperature.




MARATHON GENERATOR.STANDARD FEATURES.

Medium Voltage Alternator:


gensets

Full amortisseur winding

Disc coupling


PMG excitation



Heavy duty shielded ball bearings (min. life

of 40,000 h), regreasable


Insulation class H

Temperature rise class F

Anti-condensation heaters




voltage dip

Option





LEROY SOMER GENERATOR.STANDARD FEATURES.

Low Voltage Alternator:

Single-bearing



2/3 pitch

Disc coupling


AREP / PMG excitation

Analogue voltage regulator


Winding protection for tropical

environments

Regreasable bearings


Insulation class H

Anti-condensation heaters for





voltage dip

Option





LEROY SOMER GENERATOR.STANDARD FEATURES.

Medium Voltage Alternator:


gensets

2/3 pitch winding

Disc coupling


AREP / PMG excitation



Winding protection for tropical environments

Regreasable bearings


Insulation class H

Temperature rise class H

Anti-condensation heaters




voltage dip

Option





LOW VOLTAGE GENERATOR.COMPARISON.

Feature Marathon Leroy Somer

BearingsSingle bearing (12V & 16V)

Double bearing (20V)Single bearing (12V & 16V)

Double bearing (20V)

Bearings design regreasable regreasable

Insulation class H H

Winding pitch 2/3 2/3

Winding insulation standard tropical

Winding RTDs Included in standard scope of supply* Included in standard scope of supply*

Voltage regulation digital Analog; digital (optional)

Short-circuit current 5 sec 250% 300%

Excitation PMG AREP

Ingress protection IP23 IP23

Anti condensation heaterOptional

Standard for 20VOptional

Standard for 20V





GENERATORS.BENEFITS.

Two alternator brands available

Higher flexibility to react on tender specifications and customer requirements

Marathon as first alternator brand supplies their alternator in a special MTU design

PMG excitation as standard for Marathon alternators

Improved transient performance

Constant power supply to the AVR regardless of the generator’s terminal

voltage (no influence of transient output voltage dips)

No need for field flashing

Manufactured in the US

Leroy Somer as second alternator brand

Premium product with premium image

Manufactured in the EU (EUR1 qualified)




BASE FRAME.FEATURES & BENEFITS.

20V 4000

16V 4000

12V 4000

Components

with same

position for all

cylinder

variants

Welded base frame design most rigid design also during transportation and on-site

installation.

Same position of main components and interfaces Simplified system integration

Less height in comparison to actual Series 4000 base frame more feasable

integration into containers or buildings, easier transport.

Standard




CONTROL PANELOVERVIEW

Controller Brands:

Two controller brands as standard option available:

Basler

Deif

Common Features:

Engine monitoring and protection.

Alternator monitoring and protection

Featuring all necessary functions for protection

Featuring all necessary functions for indication

Clear text display

Programmable In- and Outputs

Circuit breaker control




PRE-WIRED CONTROL CABINET.VARIANT 1+.

Features:

Fully pre-wired control cabinet without

controller

Control cabinet has the same

dimensions as for control versions with

controller.

Dimensions: 1000 x 600 x 250 mm

Benefits:

Easy customization of different controller

types and brands

Standardized customer interface

Standard




ISLAND OPERATION.VARIANT 2.

Features:

Control cabinet incl. controller for island

operation.

Genset is always connected on a de-

energised network.

No Automatic Mains Failure (AMF)

operation

No parallel operation

Option




AUTOMATIC MAINS FAILURE OPERATION.VARIANT 3A.

Features:

Automatic Mains Failure Operation (AMF)

Controller with mains failure detection.

In case of a mains failure the genset will

start automatically.

Operation with automatic transfer switch

(ATS) with own control unit that will switch

over between mains and genset.

Switchover with a short interruption of the

supply.

No parallel operation.

GCB for Generator protection required

Option

Mains




AUTOMATIC MAINS FAILURE OPERATION.VARIANT 3B.

Features:

Automatic Mains Failure Operation

(AMF)


In case of a mains failure the genset

will start automatically.

Operation with two electrically

interlocked circuit breakers that are

controlled by the genset.

Switchover with a short interruption of

the supply.

No parallel operation

Option




ISLAND PARALLEL OPERATION.VARIANT 4.

Features:

Island parallel operation of multiple gensets in a network without mains connection

After a remote start signal the gensets start, synchronize and switch on automatically.

Load sharing

Communication via CAN-Bus

Option




SINGLE GENSET MAINS PARALLEL OPERATION.VARIANT 5 & 6.

Features (V5):

Automatic mains failure operation of a single genset.


In case of a mains failure the genset will startautomatically.

Switchover with a short interruption of the supply incase of a mains failure.

When the mains restores the genset will synchronizeto the mains for a short time Switchover withoutinterruption of supply when the mains comes back

Features (V6):

Permanent mains parallel operation of a single genset.

Peak shaving

G Mains

GB

Consumer

MCB

bus voltage sensing

Option




MULTIPLE GENSET MAINS PARALLEL OPERATION.

VARIANT 7.

Features:

Permanent mains parallel operation of multiple gensets.

The group of gensets will synchronize between each other.

Load sharing between the gensets.

Depending on the power demand the single gensets will start automatically if required.

Option




CONTROL PANELBENEFITS

The control panel can be installed on both

sides of the base frame. Easy adaption to

multiple installation situations.

Two different controller brands as standard option available:

Basler

Deif

Improved fit to customer requirements and tender specifications.

High variety of controller specific options available.

Easy customization to other controller brands due to standardized interface

(variant 1+)




CONTROL PANELAPPLICATIONS: BASLER & DEIF

Application Basler Deif

Variant 1+ -

Variant 2 Basler 2020 Deif AGC-4

Variant 3a Basler 2020 Deif AGC-4

Variant 3b Basler 2020 Deif AGC-4




Variant 7 - Deif AGC-4




CONTROL PANELCOMPARISON: BASLER & DEIF

Feature Basler Deif

Phase monitoring 3 phases for generator and mains3 phases for generator and

mains

No. of generator sets inparallel operation

16 16

Additional in-and outputs via expansion modules fully integrated in controler

Remote panel only for monitoringRemote control panel for

complete genset control andmonitoring




CIRCUIT BREAKERSFEATURES & BENEFITS

Features:

Manual & electrical actuated circuit breakers

3/4 pole

Stand-alone design

Optional cable connections GCB to generator in various lengths

Benefits:

Higher flexibility for system integration into containers and buildings.

Circuit breaker can be placed on either side of the genset

Circuit breaker can be placed in different distances to the genset

Simplified customization of the genset

Stand-alone is a manufacturer neutral concept

No dependency between alternator and circuit breaker design

No influence on other design features of the genset

Option




06PERIPHERAL COMPONENTS





BATTERIES.FEATURES & BENEFITS.

Technical Features:

Lead acid batteries

Complete harness

Base frame mounted battery brackets

Benefits:

Battery bracket covers the top of the battery

operation and maintenance staff may use the battery

brackets as step

Batteries are placed at the same position of the base

frame for all cylinder variants

Option




BATTERIE CHARGER.FEATURES & BENEFITS.

Technical Features:

AC input: 180 ~ 264VAC

130% peak load capacity

Output voltage: 27.6VDC

Output current: 40A

UI charging characteristic

Benefits:

Standard option (mounted in control cabinet) even if the genset is delivered without

controller

less efforts for the customer because a battery charger is necessary for almost

every control panel

Standard scope is reduced by the battery charging alternator

Increased genset efficiency

Lead-Acid-Battery charging alternators are not suitable for NiCad-batteries

Option




JACKET WATER HEATER.FEATURES & BENEFITS.

Technical Features:

3-phase system, 380V – 415V

Flow rate: 38 litre/min

Adjustable thermostat from 32°C to 55°C

Benefits:

Uniform engine heating due to forced circulation of

the coolant (more efficient heating than

thermo siphon tank heaters)

Extended hose life and reduced heater maintenance

due to reduced outlet temperature

Improved engine start-up

Controls for automatic operation included

Minimal material, space, and time for mounting due to

compact design

Option




LUBE OIL EXTRACTION PUMPFEATURES.

Technical Features:

Mechanical, semi rotary hand pump

Vertical installation position, suction connection at

bottom

Alternative connection for extraction pump

(switchable)

Option




FUEL CONNECTION.FEATURES & BENEFITS.

Technical Features:

Fuel flow & return lines are mounted on base frame.

Connections with valves.

Benefits:

Standardized customer interface, easier installation.

Easy connection of external fuel tanks / systems.

Option




FUEL PRE-FILTER WITH WATER SEPARATOR.FEATURES & BENEFITS.

Technical Features:

Model: SEPAR 2000.

Single filter and switchable duplex filter avaialble.

Water separator and fuel filter for light diesel fuel.

5-stage filtration (multi-stage centrifugal system).

Water level sensor.

Benefits:

Fuel flow & return lines are mounted on base frame with .

Most reliable water separator under harsh conditions.

World-wide service network

Compact design / High efficiency / Low flow restriction

Long lifetime of filter element due to 5 stage filtration; the

fuel runs through 4 filtration steps before it reach the filter

element.

Option




HEAVY DUTY AIR FILTER.FEATURES & BENEFITS.

Technical Features:

Two-stage engine air filter operating in medium

to heavy dust conditions

Proofed RadialSeal™ technology

Filter insert and filter element combined

Airflow: air inlet on side, outlet on end

Horizontal installation

Benefits:

Complete genset mounted solution no additional

efforts to add filters at the air inlets of containers or

buildings

Option




07SUMMARY





SERIES 4000 GENSET.SUMMARY.

Significant enhancement of standard options

Medium voltage alternators

Oversized alternators

Leroy Somer as second alternator brand

Deif as second controller brand

Control Variant 7 (mains parallel operation of multiple gensets)

Mechanical driven radiator for 12V and 16V gensets

Improved system integration ability

Smaller base frame (height) smaller height for genset

Same position for main components and interfaces at baseframe

Control panel can be mounted on both sides of the genset

Stand-alone circuit breaker

Pre –wired control cabinet (variant 1+)

Documents

PRODUCT PRESENTATION SERIES 4000 1500 – 3400 kVA