TB 46204 f 50

OAGD - 14.10.2011

Technical Description
GB

Genset without heat recovery box

AoE 12V4000L62
1

Ratings and Emissions

NATURAL GAS
MZ 70
Hu = 8,0-11,5 kWh/mn
90 / 78 C

For operation on
Methane number
Low heat value (LHV)
Cooling water temperature
Genset with synchronous generator
for generating
Gas mixture cooler, intern
(1st stage HT)
Gas mixture cooler, extern
(2nd stage LT)
NOx

1.1

3Ph, 50Hz
integrated
40 C
< 500

< 250

mg/mn3

Continuous Operating Data in Grid Parallel Mode

8 % tolerance for thermal outputs and 5 % for total energy input listed. Performance data in accordance with ISO 3046. All data apply to grid
parallel operation. Data for site operating conditions other than those mentioned, available on demand. Max. reactive power in kVA, resp. nominal
current acc. to nominal output of the generator.

Grid parallel
mode, only

Generator voltage
Electrical output of generator
(no overload capacity)

GB1165N5

GB1168N5

400

400

415

Thermal output
(2nd stage LT mixture cooling)
Total energy input

400
874

415
874

Thermal output
(Engine cooling / lube oil / 1st stage HT mixture cooler)
Thermal output
(2nd stage LT mixture cooling)
Total energy input

GB1165N5

GB1165N5

6300

10500

11000

1166

1165

1165

kW el

660

687

kW th

77

81

kW th

2822

2926

kW

400
873

415
873

6300
871

10500
871

11000
871

V
kW el

490

504

kW th

57

61

kW th

2169

2239

kW

Part Load Data in Grid Parallel Mode (50 %)

Generator voltage
Electrical output of generator

400
580

415
580

Thermal output
(Engine cooling / lube oil / 1st stage HT mixture cooler)
Thermal output
(2nd stage LT mixture cooling)
Total energy input

1.4

GB1166N5

Part Load Data in Grid Parallel Mode (75 %)

Generator voltage
Electrical output of generator

1.3

415

1165 1165 1168 1168

Thermal output
(Engine cooling / lube oil / 1st stage HT mixture cooler)

1.2

Grid parallel- and isolated mode

400
578

415
578

6300
576

10500
575

11000
575

V
kW el

352

352

kW th

46

43

kW th

1539

1571

kW

Continuous Operating Data in Isolated Mode

Generator voltage
Electrical output of generator

400

415

400
415
1060 1060

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

6300
1059

10500
1058

11000
1058

V
kW el

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB
1.5

Pollutant Emissions

Emission values related to dry exhaust gas with 5 % O2. (For exhaust gas volume flow see 3.5)
NOx, stated as NO2
CO, without catalyst
Formaldehyde, without catalyst
CO, with catalyst
(optional, delivered loose)
Formaldehyde, with catalyst
(optional, delivered loose)

< 500

< 1000

< 140

< 250
< 155

mg/mn3
mg/mn3
mg/mn3

< 300

mg/mn3

< 60

mg/mn3

Design Principles / Scope of Supply

Engine and flange-mounted alternator (SAE 00 housing) are connected via a torsionally resilient coupling and resiliently mounted to a
rigid, welded steel base frame.
Standby heater
Lube oil pump for draining the oil sump (incl. two solenoid valves).
The base frame is installed on vibration dampers

2.1

Engine plus Accessories

MTU 12V4000L62
V 12
170 / 210
57,20
1500
10,5
12,8:1
16,8

Otto-Gas-Engine
Cyl. arrangement, no. of cyl.
Bore / stroke
Volume
Speed
Mean piston speed
Compression ratio
Mean effective pressure
Standard power acc. to ISO 3046, (no overload capacity)
Specific full-load consumption (tolerance 5 %)
Gas consumption (based on LHV = 10,03 kWh/m3n)
Lube oil consumption
(not guaranteed, at rated load and after 1000 Oh)

mm
Litre
1/min
m/s
bar

1200
2,35
281,4

kW mech
2,44
291,7

0,3

kWh/kWhmech
m3/h
g/kWhmech

Basic Engine

Monobloc grey cast crankcase with inspection ports, flywheel housing SAE 00, flywheel 21 cast iron oil pan

Forged crankshaft
Forged connecting rods

Four-valve, individual cylinder heads with central pre-chamber armoured valves with Rotocap rotators

Light-metal solid-skirt pistons with oil cooling duct, piston cooling via oil spray nozzles

Mixture Formation
Air intake via dry-type engine-mounted air filters
Venturi type air-gas mixer with gas supply via electronically controlled gas metering valve
Turbocharging
Turbocharger for gas-air mixture compression
Two-stage mixture cooling
Throttles between mixture coolers and intake manifold
Exhaust System
Dry-type, insulated exhaust manifolds in the engine Vee
Lube Oil System
Lube oil circulation pump with safety valve for forced-feed lubrication and piston cooling
Engine mounted heat exchanger
Lube oil filters with replaceable filter elements
Engine-mounted device for automatic oil level control
Oil dipstick
Closed crankcase venting system with oil separator connected to mixture piping before turbo charger
Connections for oil refill and oil draining
Cooling System (2-circuit)

High temperature circuit for lube oil cooling, 1st stage of mixture cooling and engine jacket

Connections with counter-flanges for external cooling- or heat recovery system

Integrated cooling preheating unit

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB

Starting System
Electric starter (9 kW, 24 VDC)
Ignition System

Microprocessor-controlled high-voltage spark-ignition system with low voltage distribution, no moving parts, no wear

Automatic control for ignition energy adjustment

Variable timing control
Timing sensors at camshaft and crankshaft
One ignition coil per cylinder
Industrial spark plugs

2.2

Generator

Self-regulating, brushless revolving-field synchronous generator with built-in exciter, voltage and cos regulator, designed to VDE 0530, radio
interference class N, low-harmonic design.

Grid parallel
mode, only

Generator voltage
Rating (F)
Insulation class
Temperature-rise rating
Cos
Frequency
Speed
Efficiency (100 % load) at cos
Stator connection
Voltage tolerance
Frequency tolerance
Max. ambient temperature.
Installation altitude max.
Type of protection

400
415
1445 1445
H
H
F
F
1,0 - 0,8

97,1

97,1

Grid parallel- and isolated mode

400
415
2050 2050
H
H
F
F
1,0 - 0,8

97,3

97,3

6300
2148
F
F
1,0 - 0,8
50
1500
97,2
Star
5
5
40
1000
IP 23

10500
2167
F
F
1,0 - 0,8

97,1

11000
2270
F
F
1,0 - 0,8

97,1

V
kVA

Hz
1/min
%
%
%
C
m

*) Cos-phi must be over the whole power range in the defined range. Only inductive reactive power admissible (over-erected).
In case of nominal mains voltage variations by 2 %, an automatic voltage adjustment must be used.

2.3

Gas Supply

Gas regulation lines delivered loose, components approved per Directive for Gas Components 90/356/EWG

Gas Regulation Line

Gas filter
two solenoid valves (or double solenoid valve)
Low pressure regulator
valve leakage monitor
flexible stainless steel hose

2.4

Controller of Genset

MMC

Operation and visualization

Control of auxiliary drives (cogeneration unit / extern)
Connection / seperation of the generator to/from the grid
Control of generator and grid protection functions, see separate description "Technical Description MMC 4000 control"

ECU7

Speed governing
Air / Fuel ratio control via engine characteristic map
Engine start / stop sequence
Emergency stop sequence
Engine monitoring (temperatures, pressures, speed, etc.)

EMU7

Single exhaust temperature monitoring (cylinderhead)

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/
TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB

SAM

Providing CANopen interface

Lube oil make up
Monitoring of minimum load

Ignition

Electronic ignition system

Ignition time setting
Speed monitoring

Knocking monitoring AKR

Acoustic knocking monitoring system

Individual ignition timing adjustment per cylinder

3
3.1

Technical Data Design / Operation

Operating Media

The binding specifications for cooling water, fuel, lube oil, exhaust condensate and heating water are stipulated in the relevant MTU operating
media regulations.
Values for cooling / heating water are based on water without antifrost and corrosions additives.
Admissible antifrost and corrosions additives see operating media. Values in brackets [ ] refer to 35 % Glycol.

3.2

Filling Quantities

Lube oil quantity (first filling)

Lube oil quantity (consecutive oil changes)
Engine cooling water, HT
Mixture cooling water, LT
(without recooler and pipes)

3.3

260
220
185

Liter
Liter
Liter

20

Liter

Heat Generation

Engine Cooling (engine block with lube oil and 1st stage HT mixture cooling)
Thermal output (8 % tolerance)
Cooling water temperature, in- / outlet
Cooling water volume flow
Pressure loss
System pressure permitted max.
Cooling water temperature, min.

660

687
[60 ]
[2,4 ]

kW
C
m/h
bar
bar
C

81
23

kW
m3/h

78 / 90
56
2,1

[60 ]
[2,4 ]

56
2,1
6,0
40

Mixture Cooling (2nd stage LT)

Thermal output (8 % tolerance)
Mixture cooling water volume flow (8 % tolerance)

77
23

Inlet temperature mixture cooling water max.

Outlet temperature mixture cooling water max.

40
43

Pressure loss
System pressure permitted max.
Note information pressure control valve.

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

C
43

0,6
6,0

C
bar
bar

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB
3.4

Combustion Air / Ventilation

Heat radiated from the genset

(engine and generator without adjoining pipes)
Engine room ventilation
Minimum intake air volume flow for engine room cooling.
(The engine room ventilation has to be calculated and
adjusted according to the requirements for gaseous fuels
valid at the installation site)
Ventilation air volume flow
Combustion air volume flow
Intake air temperature min. (for other temperatures the
limit
values must be adapted after consultation)

80

85

17546

18623

m3/h

12490
4638

13273
4908

m3/h
mn3/h

Temperature difference intake / ventilation max.

3.5

15

< 20

max. permissible intake negative pressure at inlet air filter

kW

mbar

Exhaust Gas (Exhaust gas heat exchanger not included in scope of supply, optional)

Thermal output by 120 C (8 % tolerance)

Exhaust temperature
(turbocharger outlet)
Exhaust gas mass flow, dry
Exhaust gas mass flow, moist
Exhaust gas volume flow, dry
(0 C, 1013 mbar)
Exhaust gas volume flow, moist
(0 C, 1013 mbar)
Permissible back-pressure downstream of engine
min. / max.

643

682

kW

453

454

5762
6204

6104
6561

kg/h
kg/h

4371

4634

mn3/h

4890

5169

mn3/h

30 / 60

mbar

In multi-genset systems, separate exhaust piping for each genset is recommended.

If a common exhaust header system is installed, exhaust flow back into any non-operationing gensets must be avoided by use of a 100 % gastight exhaust shut-off flap.
In the range of partial load the exhaustive temperature rises up to 550 C. In case of use of catalyzers, due to the exothermic reaction the
exhaustive temperature may increase up to 600 C.

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB
3.6

Sound Levels

Engine surface noise emitted by the genset

(distance 1 m, free field measurement, Tolerance +5 dB for single 1/3-octave band, +2 db(A) for total A-weighted level)
Frequency (Hz)

Sound pressure levels (dB)

12,5
16
20
25
31,5
40
50
63
80
100
125
160
200
250
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
8000
10k

Sum of sound pressure levels (dB)

Sound power levels dB (A)

0,0
0,0
0,0
73,3
63,5
67,7
68,7
71,6
82,3
79,6
82,4
82,4
80,0
82,0
84,9
89,0
86,0
86,3
85,7
85,0
85,5
84,8
85,6
83,8
82,7
83,1
86,8
96,5
82,1
80,5

Lin dB
100,2

0,0
0,0
0,0
73,8
64,0
68,2
69,2
72,1
82,8
80,1
82,9
82,9
80,5
82,5
85,4
89,5
86,5
86,8
86,2
85,5
86,0
85,3
86,1
84,3
83,6
83,6
84,3
97,3
82,6
81,0

dB (A)
99,4
118,4

Lin dB
100,7

dB (A)
99,9
118,9

undampened Exhaust noise

(distance of 1 m from outlet, Tolerance +5 dB for single 1/3-octave band, +3 db(A) for total A-weighted level)
Frequency (Hz)

Sound pressure levels (dB)

12,5
16
20
25
31,5
40
50
63
80
100
125
160
200
250
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000
5000
6300
8000
10k

Sum of sound pressure levels (dB)

Sound power levels dB (A)

0,0
0,0
0,0
78,5
76,6
83,9
94,7
101,1
113,5
107,1
110,0
111,9
111,6
100,4
101,6
99,4
97,5
93,7
89,6
84,5
87,9
87,8
86,6
85,0
83,4
80,0
85,6
82,9
64,0
51,1

Lin dB
118,7

0,0
0,0
0,0
79,0
77,1
84,4
95,2
101,6
114,0
107,6
110,5
112,4
112,1
100,9
102,1
99,9
98,0
94,2
90,1
85,0
88,4
88,3
87,1
85,5
83,9
80,5
86,1
83,4
64,5
51,6

dB (A)
106
118,6

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

Lin dB
119,2

dB (A)
106,5
119,1

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TB 46204 f 50
OAGD - 14.10.2011

Technical Description
GB
3.7

Connections

Unless stated otherwise, the connecting flanges are to DIN 2501.

Nominal diameters and pressures are as follows:
Safety gas line *
Exhaust gas outlet (expansion joint)

DN80 / PN16
DN250 / PN6

Cooling water in- / outlet

DN100 / PN16

Mixture cooling water in- / outlet

DN50 / PN16

Lube oil flow and return: Tube connection to DIN 3861

d = 22

*) Dimension depending on gas pressure and gas quality

3.8

Paints, Dimensions and Weights of the Genset

Engine and Generator

Frame
Length
Width
Height

RAL 9006
RAL 5002
4450 (4700*)
1850
2400

mm
mm
mm

Genset (dry weight) 400 V

11000 (11750*)

kg

Genset (dry weight), mean volatge

Genset (service weight)
Genset (service weight), mean voltage
For binding dimensions please refer to drawing.

13000
11500 (12250*)
13500

kg
kg
kg

*) Isolated mode

Dimensions and weight may vary according to the alternator type (voltage rating)
Data are subject to change without notice in the interest of further development.

AoE 12V4000L62 /1500/12,8:1/70/9078/omKat/500 250/

TVU 2010-09-10 / TA 733517e 733516e / TVU 2010-09-13 / 1/2TA 733903e 733902e

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