Series 2000 G05

Series 2000 G05

OAC-O
Friedrichshafen, March 2009

March 2009 Volkert_OAC-O 1

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

Agenda Series 2000 G05

1.
1. Configuration
Configuration // Main
Main Data
Data 
 Slide
Slide 03-04
03-04

2.
2. Ratings
Ratings 
 Slide
Slide 07-11
07-11

3.
3. Emission
Emission 
 Slide
Slide 12-13
12-13

4.
4. Engine
Engine Controller
Controller 
 Slide
Slide 14
14

5.
5. Engine
Engine Management
Management 
 Slide
Slide 15-22
15-22

6.
6. Engine
Engine Configuration
Configuration 
 Slide
Slide 23-36
23-36

March 2009 Volkert_OAC-O 2

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

1.1 Configuration Series 2000 G05

Pump Drive System

UPS Application (on request)

2000 G05

Emergency Power System

Standby Power

Continuous & Prime Power System

March 2009 Volkert_OAC-O 3

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

1.2.1 Main Data Series 2000 G05

Technical Data
Cylinder versions: 12/16/18V 2000
Stroke / Bore: 150 mm/130 mm
Displacement: 1,99 l/Zyl.
Injection System: PLD
Compression Ratio: Eps = 16
Turbocharging: Single Stage
Exhaust System: Dry
Electronic: ADEC & SAM
Cooling System: - Internal Charge Air
Cooling System (TB)
- External Charge Air
Cooling System (TD)
TD Version
Optimization: 50 Hz - Fuel Consumption
- TA-Luft (1500 NOX)
60 Hz - EPA Tier II
Same Dimensions and Weight compared to G03/ G04

March 2009 Volkert_OAC-O 4

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

1.2.2 Time schedule Series 2000 G05

TVU Data March 2007

Installation Drawings March 2007
Start of Delivery 50Hz FC optimized September 2007
Start of Delivery 50Hz emission opt. September 2007
Start of Delivery 60Hz FN EPA Tier 2 January 2008
Start of Delivery 60Hz DT EPA Tier 2 January 2008
2006 2007 2008

March 2009 Volkert_OAC-O 5

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

1.3 Main Data Series 2000 G05

Dimensions

Engine Dimensions L x W x H Mass dry

TD mm (in) kg (lbs)
12V 1882 x 1580 x 1585 (74 x 62 x 62) 2490 (5490)
16V 2226 x 1580 x 1585 (88 x 69 x 79) 3100 (6835)
18V 2398 x 1580 x 1620 (95 x 69 x 79) 3500 (7715)

Engine Dimensions L x W x H Mass dry

TB mm (in) kg (lbs)
12V 1836 x 1580 x 1585 (72 x 62 x 62) 2570 (5665)
16V 2180 x 1580 x 1585 (86 x 62 x 62) 3180 (7010)
18V 2352 x 1580 x 1620 (93 x 62 x 64) 3580 (7715)

All dimensions are approximate; for complete information refer to the installation drawing
Same dimensions as G03/G04

March 2009 Volkert_OAC-O 6

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

2.1 Engine Rating Series 2000 G05

50 Hz 60 Hz

Application 3D 3B Application 3D 3B
group Standby Prime group Standby Prime
Power Power Power Power
Load factor < 85 % < 75 % Load factor < 85 % < 75 %
Operating hours Max. 500 Unre- Operating hours Max. 500 Unre-
/ year stricted / year stricted
Rating definition Fuel 10% Rating definition Fuel 10%
DIN ISO 3046 stop overload DIN ISO 3046 stop overload
SAEJ1995 / power capacity SAEJ1995 / power capacity
J1349 (ICFN) (ICXN) J1349 (ICFN) (ICXN)
Engine model kW at 1500/min Engine model kW at 1800/min
Optimization   or  Optimization  
12V 2000 G25 635 580 12V 2000 G45 780 710
12V 2000 G65 765 695 12V 2000 G85 890 810
16V 2000 G25 890 810 16V 2000 G45 1010 915
16V 2000 G65 975 890 16V 2000 G85 1115 1010
18V 2000 G65 1100 1000 18V 2000 G85 1310 1191

Optimization:

Fan power requirement not considered  Exhaust emission (TA-Luft)

 Exhaust emission (EPA 40 CFR 89 / Tier 2)
Continuous application on request  Fuel consumption

March 2009 Volkert_OAC-O 7

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

2.2 Comparison Power Ratings 50 Hz - G03 versus G05 Series 2000 G05

Power Ratings 50 Hz

2000 G03 2000 G05 2000 G03 2000 G05

kW kVA 3D 3D 3B 3B
1100 18V 2000 G63 18V 2000 G65
1200

1000 16V 2000 G63 18V 2000 G65

1100 16V 2000 G65

900 1000 16V 2000 G23 16V 2000 G25 18V 2000 G63 16V 2000 G65
50 Hz – 1500 / min

800 16V 2000 G63 16V 2000 G25

900
12V 2000 G65
16V 2000 G23
700 800 12V 2000 G65
12V 2000 G63
750
12V 2000 G25
700 12V 2000 G23 12V 2000 G25 12V 2000 G63
600
600 12V 2000 G23

500
500
400
400
350
300
Electrical outputs may vary depending on alternator efficiency / radiator fan
consumption / ambient conditions

March 2009 Volkert_OAC-O 8

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

2.3 Ratings 50 Hz Prime Power 3B Series 2000 G05

Fuel-optimized and exhaust emissions-optimized ratings

Present Ratings G03 New Ratings G05

S2000G03 S2000G05
565 kW 580 kW
12V 2000 G23
650 kVA + 3% 12V 2000 G25
650 kVA
625 kW 695 kW
12V 2000 G63
700 kVA + 11% 12V 2000 G65
800 kVA
720 kW 800 kW
16V 2000 G23
800 kVA + 11% 16V 2000 G25
900 kVA
805 kW 890 kW
16V 2000 G63
900 kVA + 11% 16V 2000 G65
1000 kVA
895 kW 1000 kW
18V 2000 G63
1000 kVA + 12% 18V 2000 G65
1130 kVA

March 2009 Volkert_OAC-O 9

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

2.4 Comparison Power Ratings 60 Hz - G03 versus G05 Series 2000 G05

Power Ratings 60 Hz

2000 G03 2000 G05 2000 G03 2000 G05

kW kW el
3D 3D 3B 3B
18V 2000 G85
1300
18V 2000 G83
1100
1200 18V 2000 G85

16V 2000 G83 16V 2000 G85

1100 1000
60 Hz – 1800 / min

18V 2000 G83

1000 16V 2000 G43 16V 2000 G45 16V 2000 G83 16V 2000 G85
900

900 16V 2000 G43 16V 2000 G45

800 12V 2000 G85
750 12V 2000 G83 12V 2000 G85
800
700 12V 2000 G45
12V 2000 G83
12V 2000 G43 12V 2000 G45
700 12V 2000 G43
600

600
500

500
Electrical outputs may vary depending on alternator efficiency / radiator fan
consumption / ambient conditions

March 2009 Volkert_OAC-O 10

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

2.5 Ratings 60 Hz Prime Power 3D Series 2000 G05

EPA-Tier II certified
Present Ratings G03 New Ratings G05

S2000G03 – EPA Tier I S2000G05 – EPA Tier II

735 kW 780 kW
12V 2000 G43
650 kWe + 6% 12V 2000 G45
700 kWe
835 kW 890 kW
12V 2000 G83
750 kWe + 6% 12V 2000 G85
800 kWe
1007 kW 1010 kW
16V 2000 G43
900 kWe - 16V 2000 G45
900 kWe
1115 kW 1115 kW
16V 2000 G83
1000 kWe - 16V 2000 G85
1000 kWe
1250 kW 1310 kW
18V 2000 G83
1100 kWe + 5% 18V 2000 G85
1200 kWe

March 2009 Volkert_OAC-O 11

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

3.1 S2000: New standards in exhaust emissions Series 2000 G05

Series 2000 G03 Series 2000 G05

• NOX ≤ 2000 mg/m3N (5% O2) • NOX ≤ 1500 mg/m3N (5% O2)

• Dust ≤ 50 mg/m3N • Dust ≤ 20 mg/m3N

Exhaust emission
• HC ≤ 150 mg/m3N TA – Luft * • HC ≤ 150 mg/m3N
optimized
• CO ≤ 600 mg/m3N • CO ≤ 300 mg/m3N
• Formaldehyde ≤ 60 mg/m3N • Formaldehyde ≤ 20 mg/m3N
• NOX ≤ 9,2 g/kWh
Exhaust emission • NOX + HC ≤ 6,4 g/kWh
• PM ≤ 0,54 g/KWh EPA
optimized • Dust ≤ 0,2 g/kWh
• HC ≤ 1,3 g/kWh
• CO ≤ 3,5 g/kWh
• CO ≤ 11,4 g/kWh

• Emissions on request • Emissions on request

• Fuel Consumption Fuel consumption • Fuel Consumption
Fuel
≈ 195g/kWh (50Hz / 3B) optimized ≈ 195g/kWh (50Hz / 3B)

* The emission datas are valid between 50% - 100% power

March 2009 Volkert_OAC-O 12
 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

3.2 EPA standards USA Series 2000 G05

USA EPA Standards Define Several Steps To Significantly Reduce Emissions Until Year 2015

kW (HP) 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
0-7 (0 - 10) ( 10.5 ) / 8.0 / 1.0 ( 7.5 ) / 8.0 / 0.80
( 7.5 ) / 6.6 / 0.40
8 - 18 (11 - 24) ( 9.5 ) / 6.6 / 0.80 ( 7.5 ) / 6.6 / 0.80
19 - 36 (25 - 48) ( 9.5 ) / 5.5 / 0.80 ( 7.5 ) / 5.5 / 0.60 ( 7.5 ) / 5.5 / 0.30
( 4.7 ) / 5.0 / 0.03
37 - 55 (49 - 74) ( 4.7 ) / 5.0 / 0.30
9.2 / - / - / - ( 7.5 ) / 5.5 / 0.60
56 - 74 (75 - 99) ( 4.7 ) / 5.0 / 0.40
3.5/0.1 5.0/0.02 0.40/0.19/5.0/0.02
75 - 129 (100 - 173) 9.2 / - / - / - ( 6.6 ) / 5.0 / 0.30 ( 4.0 ) / 5.0 / 0.30

130 - 224 (174 - 301) 9.2 / 1.3 / 11.4 / 0.54 ( 6.6 ) / 3.5 / 0.20 ( 4.0 ) / 3.5 / 0.20

225 - 449 (302 - 602) 9.2 / 1.3 / 11.4 / 0.54 ( 6.4 ) / 3.5 / 0.20 ( 4.0 ) / 3.5 / 0.20 2.0/0.19/3.5/0.02 0.40 / 0.19 / 3.5 / 0.02
450 - 560 (603 - 751) 9.2 / 1.3 / 11.4 / 0.54 ( 6.4 ) / 3.5 / 0.20 ( 4.0 ) / 3.5 / 0.20

9.2 / 1.3 / 11.4 / 0.54 (6.4 ) / 3.5 / 0.20 3.5/0.40/3.5/0.10 3.5/0.19/3.5/0.04

>560 (>751)
NOX / HC / CO / PM (NOX+NMHC) / CO / PM 0.67/0.40/3.5/0.10* 0.67/0.40/3.5/0.03**

NOx/HC/CO/PM Tier 1 Tier 2 Tier 3 Tier 4 Interim Tier 4 Final

(NOx+NMHC)/CO/PM * Applies to portable power generation >1200 hp

in g/kWh ** Applies to portable power generation >751 hp

March 2009 Volkert_OAC-O 13

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

4.1 From MDEC to ADEC Series 2000 G05

MDEC (MTU Diesel Engine Controller) NEW ADEC (Advanced Diesel Engine Controller)
-Injection: triple
-Injector voltage: 24 - 48V
-Computing velocity: 800 %
compared to MDEC
-Input/Output
Channels. 90
-Max. operating
temperature: 105°C

PLUG X1 PLUG X2 PLUG X4 PLUG X3

• Engine speed control System cabel Sensor Harness Injector Harness Power Supply
• Engine monitoring and display of engine operating parameters
• Engine protection on
• Self diagnosis and monitoring system for hard and software • Torque based engine management
• Load profile recorder • Additional Input/Output Channels
• Automatic start sequence control
extended
• Increased Computing Performance
• Speed selection 50 or 60 Hz function,
• Multiple Injection Capability
• Droop adjustable future • Increased Temperature Operating Range
trend • Flexible Customer Interface and Plant Adaption via
Service and Application Module (SAM)

March 2009 Volkert_OAC-O 14

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.1 System Integration Series 2000 G05

LCD - Display
Analog

Gauges

Control
Alternator Cabinet
Engine

ADEC SAM +
DiaSys
Network
(CAN BUS)

March 2009 Volkert_OAC-O 15

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.2.1 SAM Functions Series 2000 G05

SAM Basic SAM Option: SAM Plus

• Redundant Data • Fuel Level
Storage For installation Monitoring
• Life Data in switchgear cabinet, service • Load Step Control
Storage voltage 24 VDC, data • Preheating Control
communication with ADEC
• CAN BUS via CAN-BUS • Day Tank /
Communication Storage Tank Control
• Operating Signals • Fuel Pump Control
• Fault Codes • Circulation Pump Cont.
• Warnings / • Shutter Control
Alarms • Fan Control
• Webserver • Fuel Prefilter Monitor.
Access • Gen. Wind. Temp. Mon.
• Remote • Gen. Excitation Conf.
Control • Second Softw.Conf.

March 2009 Volkert_OAC-O 16

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.2.2 SAM Functions Series 2000 G05

SAM (Service and Application Module)

CAN open & Compact Flash Display for
J 1939 in one card Memory Card Fault-Codes
for Applikation Software and Mini-Dialog

Pushbutton for
Slots for additional Mini-Dialog
I/O Plugin Cards

Plugs with spring Diagnostic-

loaded terminal strips Lamp

Ethernet Interface
for Remote Diagnostics Interface to Dialog-
and Web Based Monitoring Unit

March 2009 Volkert_OAC-O 17

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.2.3 Logistic- and Data Storage- Concept Series 2000 G05

CAN BUS Communication between ADEC and SAM

ADEC SAM

Life data storage

• Engine life data is
stored continuously
Every hour
MCS5 CAN BUS After every engine
stop or emergency
Engine life data stop
• Stored in the SAM-
• engine hours
memory as a
• error log
backup
• load profile

• Application/Engine Software • Download of complete software is initiated

stored in SAM and ADEC automatically after connecting a new ADEC

March 2009 Volkert_OAC-O 18

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.2.4 Dialog Connection to SAM Series 2000 G05

1. Diagnostic System 2. Select: USB or PCMCIA 3. SAM

2a. USB to CAN Converter 2b. PCMCIA to CAN Converter

Interface
for Dialog unit

CAN Dialog cable

2m, 9pol. Sub D / 12pol. round connector

March 2009 Volkert_OAC-O 19

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.3.1 ESCM (Engine Site Condition Management System) Series 2000 G05

Primary Purpose of ESCM:

-- > Engine Protection under all Extreme Site Conditions
-- > Engine Operation is automatically adapted to Site Conditions

NORMAL ENGINE
OPERATION • High Ambient Temperature PROTECTION
MODE MODE
• Normal fuelling • High Altitude Operation • Reduced
rate and torque maximum torque
limit limit
• Normal injection • Increased Intake Air Restriction • Advanced injection
timing timing (close to
rated power)
• Standard • Increased Exhaust Backpressure • Adapted
DBR-Curve DBR-Curve

• Increased Approach Temperature

March 2009 Volkert_OAC-O 20

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

5.3.2 ESCM (Engine Site Condition Management System) Series 2000 G05

Series: S4000 Gx1, S4000 Gx2, S2000 Gx3 Series: S4000 Gx3, S2000 Gx4, S2000 Gx5

Controller: MDEC Controller: ADEC

- Engine Power will be determined based on the - Engine Power is adapted fully automatically to the
Reduction Table acc. to DIN/ ISO 3046 site conditions by the ESCM inside ADEC
(Reduction Factors) - ESCM- Calculation Tool to determine the Relevant
- Engine Power Limitation on Plant Site necessary !! Site Conditions for Each Rating, Application Group
and Emission Optimization
- Power Reduction very conservative
- Enter Site Conditions and the relevant Engine
- Same Reduction Rate for all Engines Power will be shown directly

March 2009 Volkert_OAC-O 21

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.1 Engine Configuration / Overview Series 2000 G05

Overview Engine Configuration

Starting
System Scope Of Other
(G01.XX) Supply

Fuel Applicat.
System /Optimiz.
(G02.XX) (G00.XX)

Lube Oil Paintwork

System Document./
(G03.XX) (G15. /G16.)

Combustion Engine
Air System Management
(G04.XX) (G09.XX)

Exhaust Cooling Engine Power Trans-

System System Mounting mission
(G05.XX) (G06.XX) (G07.XX) (G08.XX)

March 2009 Volkert_OAC-O 22

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.2.1 Scope of supply Series 2000 G05

Basic engine configuration – Stationary Power Generation Series 2000 with Air / Water Charge Air Cooling
G00.10: Basic engine G01.xx: Starting system
Grey cast-iron crankcase 1 electric starter (24VDC / 2-pole)
Flywheel housing SAE 0
Flywheel 18“ G02.xx: Fuel system
Oil pan Electronically controlled high-pressure injection with
Forged crankshaft single unit injection pumps (PLD)
Forged connection rods Fuel delivery pump
Four-valve, individual cylinder heads Fuel main filter
Light-metal solid-skirt pistons Fuel priming pump for initial system filling and venting
Piston cooling via oil spray nozzle Closed fuel system
Dry exhaust manifolds Engine standard version for fuel consumption-
Vibration damper optimized operation
All nessary on-engine air, exhaust, coolant, fuel G03.xx: Lube oil system
and oil pipework Forced-feed lubrication system with piston cooling
Lube oil circulation pump with safety valve
Lube oil multi-stage filter
Lube oil heat exchanger
Factory acceptance test (Basic Engine) Oil filter neck and oil dipstick for measurement on non-
Engine standard factory acceptance testing running engine
Engine internal preservation Closed crankcase venting system

March 2009 Volkert_OAC-O 23

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.2.2 Scope of supply Series 2000 G05

Basic engine configuration – Stationary Power Generation Series 2000 with Air / Water Charge Air Cooling
G04.xx: Combustion air system G09.xx: Engine management system
Exhaust turbochargers Integrated electronic engine control and
Intercooler, integrated in radiator monitoring system ADEC for
Set of dry-type air filters with contamination indicator -Engine speed control
G06.xx:Cooling system -Engine monitoring and display of engine operating
Coolant circulation pump and coolant thermostat for parameters and alarms
jacket water (and charge air TB) cooling circuit -Engine protection against exceeding critical operating
Engine-mounted fan drive (TD) parameters
Front-type radiator for jacket water and charge air -Automatic start sequence control
cooling circuit with integrated expansion tank (TD) -Acquisition and display of plant-related measured data
Coolant level sensor (TD) -Communication with an external system
G07.xx: Engine mounting G15.xx: Paintwork
Set of engine mounting brackets at engine free and Standard paintwork, single-coat, water-based paint,
driving end brilliant blue, RAL 5007
G18.xx: Packing G16.xx: Documentation
Container-transportation standard packing Set of standard operating and maintanance
documentation

March 2009 Volkert_OAC-O 24

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.3 Starting System Series 2000 G05

Standard
• Electric starter (24 VDC / 2-pole)

• G01.40: compressed air starter motor electric starting valve (24VDC),

Options with electric starting valve (24 VDC) make: Gali (type A-17, max. 30bar)
make: Gali (type A-17, max. 30bar) Electric starter and compressed air starter motor with
make: Gali (type A-27, max. 30bar) electric starting valve (24VDC),
• G01.50: redundant starting system, consisting of: make: Gali (type A-17, max. 30bar)
2 electric starter • G01.90: battery charging alternator, V-belt driven,
• G01.51: redundant starting system, consisting of: make: Bosch (28VDC / 80A)
electric starter and compressed air starter motor with • G01.91: battery charging alternator, V-belt driven,
make: Delco (28VDC / 70A)

March 2009 Volkert_OAC-O 25

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.4 Fuel System - Scope Series 2000 G05

Standard
• Electronically controlled high-pressure
injection with single unit injection pumps (EUP)
• Fuel delivery pump
• Fuel main filter
• Fuel priming pump for initial system filling and
venting
• Closed fuel system
• Engine standard version for fuel consumption-
optimized operation

Options
• G02.20: Fuel pre-filter with connections parts for installation
before low pressure fuel pump
• G02.30: Special fuel pre-filter, selectable with water
seperator and water-level sensor

March 2009 Volkert_OAC-O 26

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.5 Lube Oil System Series 2000 G05

Standard
• Forced-feed lubrication system with piston
cooling
• Lube oil circulation pump with safety valve
• Lube oil multi-stage filter
• Lube oil heat exchanger
• Oil filler neck and oil dipstick for
measurement on non-running engine
• Closed crankcase venting system

Options • G03.26: Open crankcase without return to combustion air

system
• G03.40: Hand pump for lube oil extraction
• G03.60: Electrical interval pre-lubrication pump (230/400
VAC / 3 ph / 50/60 Hz / 0.75 kW) with connecting parts
• G03.61: Set of connecting parts for interval pre-lubrication
pump

March 2009 Volkert_OAC-O 27

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.6 Combustion Air System Series 2000 G05

Standard
• Exhaust turbochargers
• Intercooler on engine (TB),
integrated in radiator (TD)
• Set of dry-type air filters with
contamination indicator

Options
• G04.11: Set of dry-type air filters with pre-separator, safety
element, contamination indicator, rain cap and mounting parts

March 2009 Volkert_OAC-O 28

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.7 Exhaust System Series 2000 G05

Options • G05.10: Set bellows (2 off) with gaskets and companion flanges
for connection to exhaust bellow
• G05.11: Set companion flanges (2 off) with gaskets for
connection to exhaust bellow

March 2009 Volkert_OAC-O 29

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.8 Cooling System / charge air cooling Series 2000 G05

Standard
• Coolant circulation pump and coolant
thermostat for jacket water (and charge
air TB ) cooling system
• Engine-mounted fan drive (TD)
• Front-type radiator for jacket water and
charge air cooling circuit with integrated
expansion tank (TD)
• Coolant level sensor (TD)

Options • G06.62: Radiator-Cooler with mechanically driven fan for engines with
air charge cooling with connecting parts for engine coolant circuit
• G06.30 (TB): V-belt drive without belt tensinoner, without fan
fan speed 1500 rpm
designed for 100% engine power, cooling air pressure loss 200 Pa. fan speed 1800 rpm
50°C /122°F ambient air temperature. • G06.31 (TB): V-belt drive without belt tensinoner, without fan
In place of item G06.61 selective fan speed:
• G06.69: Radiator-Cooler design for cooling air pressure loss of 300Pa 945, 1005, 1140, 1200 or 1290 rpm
1134, 1206, 1368, 1440 or 1548 rpm
• G06.40 (TB): Radiator-Cooler with electric driven fan for
separate installation

March 2009 Volkert_OAC-O 30

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.9 Cooling System / Coolant Preheating Series 2000 G05

Standard
• Coolant circulation pump and coolant
thermostat for jacket water (and charge
air TB ) cooling system
• Engine-mounted fan drive (TD)
• Front-type radiator for jacket water and
charge air cooling circuit with integrated
expansion tank (TD)
• Coolant level sensor (TD)

• G06.70: Set of connecting parts for preheating unit

• G06.72: Electric coolant preheating unit with circulating pump,
Options non-return flap and thermostat
(230 V / 1 ph / 50 Hz / 3kW)
(230 V / 1 ph / 60 Hz / 3kW)
• G06.73: Electric coolant preheating unit with circulating pump,
non-return flap and thermostat
(400 VAC / 3 ph / 50 Hz / 6,75kW) respectively
(440 VAC / 3 ph / 60 Hz / 9kW)
• G06.74: Electric coolant preheating unit with circulating pump,
non-return flap and thermostat
(400 VAC / 3 ph / 50 Hz / 9kW) respectively
(440 VAC / 3 ph / 60 Hz / 12kW)

March 2009 Volkert_OAC-O 31

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.10 Engine Mounting Series 2000 G05

Standard
• Set of engine mounting brackets at engine
free and driving end

Options • G07.32: Resilient engine mounts (Rubber Elements) • G07.50: Engine mounting brackets for rigid mounting on engine free end
on engine free end and driving end and driving end
• G07.34: Resilient alternator mounting elements (Rubber
Elements)
• G07.35: Resilient alternator mounting elements (Rubber
Elements)

March 2009 Volkert_OAC-O 32

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.11.1 Engine Management Series 2000 G05

Standard Options
Engine speed control

Integrated electronic engine control and

monitoring system ADEC for
• Engine speed control
• G09.12: Speed setting analog (0-10 VDC)
• Engine monitoring and display of engine (usable range 1-9 VDC)
operating parameters and alarms Speed setting range 1400 – 1600 rpm (50Hz)
Speed setting range 1700 – 1900 rpm (60Hz)
• Engine protection when exceeding critical • G09.13: Speed setting analog (0-5 VDC)
operating parameters Speed setting range 1450 – 1550 rpm (50Hz)
Speed setting range 1750 – 1850 rpm (60Hz)
• Automatic start sequence control • G09.14: Speed setting analog (4-20 mA)
Speed setting range 1400 – 1600 rpm (50Hz)
• Acquisition and display of plant-related Speed setting range 1700 – 1900 rpm (60Hz)
measured data • G09.16: Selectable droop
Droop setting 1: …% (for operation in network)
• Communication with external systems Droop setting 2: …% (for stand-alone operation)

March 2009 Volkert_OAC-O 33

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.11.2 Engine Management Series 2000 G05

Standard Options
Governor configurations for speed- and VSG governor

Integrated electronic engine control and

monitoring system ADEC for • G09.31: ADEC governor control response
No engine shut-down in case of sensor malfuction
• Engine speed control
• Engine monitoring and display of engine
operating parameters and alarms
• Engine protection when exceeding critical Cable sets for speed- and VSG governor
operating parameters
• Automatic start sequence control • G09.41: Set of Cables W 003 (for ADEC power supply) and
W 004 (interface cable), length 15m
• Acquisition and display of plant-related • G09.42: Set of Cables W 003 (for ADEC power supply) and
measured data W 004 (interface cable), length 25m
• Communication with external systems
including set of cables W003 and W004,
length 10m

March 2009 Volkert_OAC-O 34

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

6.11.3 Engine Management Series 2000 G05

Standard Options
Monitoring, Displays

Integrated electronic engine control and

monitoring system ADEC for • G10.21: SAM-Plus
• G10.22: Bus card (CCB 2) for connection to a non MTU-Controller via
• Engine speed control CANOPEN / SAE J1939. Note: Communication between engine and
controller must be certified by MTU
• Engine monitoring and display of engine • G10.30: DISPLAY DIS10 – LCD monitor
operating parameters and alarms Monitoring of relevant operating values and alarms
• G10.31: Lube oil temperature gauge, round version (52mm diameter)
• Engine protection when exceeding critical • G10.32: Engine speed gauge, round versions (72mm diameter)
operating parameters • G10.33: Lube oil pressure gauge, round versions (52mm diameter)
• G10.34: Coolant temperature gauge, round versions (52mm diameter)
• Automatic start sequence control • G10.35: DC/DC transformer for maximum 8 gauges, for power supply
• Acquisition and display of plant-related
• G10.41 (TB): Coolant level sensor with cable (15m)
measured data (Bedia sensor, magnetic-inductive)
• Communication with external systems for installation in coolant circuit expansion tank
• G10.42 TB): Coolant level sensor with cable (25m)
(Bedia sensor, magnetic-inductive)
for installation in coolant circuit expansion tank

March 2009 Volkert_OAC-O 35

 Agenda
Agenda 1.1.Config.
Config.//Main
MainData
Data 2.2.Ratings
Ratings 3.3.Emissions
Emissions 4.4.Engine
EngineController
Controller 5.5.Engine
EngineManagement
Management 6.6.Engine
EngineConfiguration
Configuration

A. Backup: SDMO / Kohler Series 2000 G05

1. Diagnostic System 2. choice: USB or PCMCIA 3. MAU (Medium Attadient Unit)

2a. USB to CAN Converter 2b. PCMCIA to CAN Converter

Interface
for Dialog unit

CAN Dialog cable

2m, 9pol. Sub D / 12pol. round connector

March 2009 Volkert_OAC-O 36