Installation Conditions: Gas Engine-Generator Sets With Series 400, Series 500, and Series 4000 Engines

Installation Conditions
Gas engine-generator sets

with Series 400, Series 500, and Series 4000 engines
MS65032/06E
Product name Engine model Application * Product name Engine model Application *
MTU 6R400 GS E3066Z5 3A MTU 8V4000 GS 8V4000L32 3A
MTU 6R400 GS B3066Z8 3A MTU 8V4000 GS 8V4000L33 3A
Reduced power
MTU 6R400 GS E3066Lx 3A MTU 8V4000 GS 8V4000L33 3A
MTU 6R400 GS E3066LHx 3A MTU 8V4000 GS 8V4000L64 3A
MTU 6R400 GS E3066D3 3A MTU 8V4000 GS 8V4000L64FNER 3A
MTU 6R400 GS E3066DH3 3A MTU 12V4000 GS 12V4000L32 3A
MTU 6R400 GS E3066D4 3A MTU 12V4000 GS 12V4000L33 3A
Reduced power
MTU 6R400 GS E3066DH4 3A MTU 12V4000 GS 12V4000L33 3A
MTU 12V400 GS E3042Z6 3A MTU 12V4000 GS 12V4000L64 3A
MTU 12V400 GS B3042Z7 3A MTU 12V4000 GS 12V4000L64FNER 3A
MTU 12V400 GS E3042Lx 3A MTU 16V4000 GS 16V4000L32 3A
MTU 12V400 GS E3042LHx 3A MTU 16V4000 GS 16V4000L33 3A
Reduced power
MTU 12V400 GS E3042D3 3A MTU 16V4000 GS 16V4000L33 3A
MTU 12V400 GS E3042DH3 3A MTU 16V4000 GS 16V4000L64 3A
MTU 12V400 GS E3042D4 3A MTU 16V4000 GS 16V4000L64FNER 3A
MTU 12V400 GS E3042DH4 3A MTU 20V4000 GS 20V4000L32 3A
MTU 6R500 GS E406-ct80 3A MTU 20V4000 GS 20V4000L33 3A
Reduced power
MTU 6R500 GS B406-ct135 3A MTU 20V4000 GS 20V4000L33 3A
MTU 8V500 GS E408-ct80 3A MTU 20V4000 GS 20V4000L64 3A
MTU 8V500 GS B408-ct135 3A MTU 20V4000 GS 20V4000L64FNER 3A
MTU 12V500 GS E412-ct80 3A
MTU 12V500 GS B412-ct135 3A
*
Continuous operation, unrestricted
Table 1: Applicability
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Table of Contents
1 Preface 9 Lube Oil System, Lube Oil Circuit
1.1 Preface 4 9.1 Extended lube oil system 33
2 Product Information 10 Exhaust System

2.1 Product safety 5 10.1 Exhaust system 35
10.2 Exhaust line 38
3 Requirements for Building and Foundation 10.3 Exhaust silencer 40
10.4 Catalytic converter 41
3.1 General requirements 6 10.5 Exhaust gas heat exchanger 43
4 Room Information 11 Insulation

4.1 Premises – Requirements 7 11.1 Insulation 44
4.2 Installation compartment – Requirements 8
4.3 Switchgear room – Requirements 11 12 Control
4.4 Installation recommendations 12
12.1 Safety functions and protective circuits 45
5 Ventilation 12.2 Quality of safety components 47
5.1 Ventilation system 13 13 Generator Circuit Breaker

5.2 Combustion air supply 16
5.3 Room-air supply 17 13.1 Selection criteria for generator circuit
5.4 Room air flow rate 18 breaker 49
5.5 Safety requirements for the ventilation
system 19 14 Mains Circuit Breaker
6 Gas System 14.1 Selection criteria for mains circuit breaker 50
6.1 Customer-provided gas system 21 15 Cabling

6.2 Requirements for the customer-provided gas
system 22 15.1 Electromagnetic compatibility and lines 51
6.3 Required gas quality 23 15.2 Cable routing 52
15.3 Cable recommendations for the various line
7 Coolant Circuit, General groups 53
15.4 Cross-sectional areas of cables 56
7.1 Coolant circuits 24 15.5 Generator wiring 57
7.2 Application as pure electricity generator 25 15.6 Protective equipotential bonding and
7.3 Application with heat recovery 26 protective conductor 58
7.4 Application with exhaust gas heat recovery 27 15.7 Electrical integration (only applicable to
7.5 Coolant circuits – Design 28 Series 4000) 59
7.6 Emergency recooler 30
DCL-ID: 0000038771 - 009
16 Appendix A
8 Connection Regulations
16.1 Index 61
8.1 Pipes and connections 31
MS65032/06E 2021-01 | Table of Contents | 3

1 Preface
1.1 Preface
These Installation Conditions form the basic principles for application engineers, system/component design-
ers and assembly personnel for planning or carrying out the installation of MTU components.
The Installation Conditions are applicable to all systems and gas engines of Series 400, Series 500, and Ser-
ies 4000 supplied by MTU, see (→ Business Portal).
The Installation Conditions do not relieve those responsible for the system from independently ensuring that
the equipment is installed and checked in an appropriate manner.
The following accompanying documents must be complied with, in addition to the Installation Conditions:
• Planning drawing
• Schematic diagrams
• TEN data
• Arrangement drawings
• Operating Instructions, see (→ Business Portal)
• Maintenance Schedule, see (→ Business Portal)
• Fluids and Lubricants Specifications, see (→ Business Portal)
• MTU standards
Refer to the specifications for the order concerned for information as to which documents apply.
Performing prescribed maintenance tasks properly and on schedule positively influences operational safety,
reliability and service life. Ensure good accessibility for operation, maintenance and repair work when plan-
ning and installing the system.
Highlighted information
Important
This field contains product information which is important or useful for the user.
This information must not refer to hazards related to personal injury or material damage.
Definition of MTU
MTU refers to Rolls-Royce Power Systems AG and MTU Friedrichshafen GmbH or an affiliated company pur-
suant to Section §15 AktG (German Stock Corporation Act) or a controlled company (joint venture).
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4 | Preface | MS65032/06E 2021-01

2 Product Information
2.1 Product safety
CE conformity of products from MTU
The products from MTU are designed and built in accordance with the Machinery Directive as well as other
relevant EC directives. MTU issues a CE Declaration of Conformity for complete machines according to the
scope of delivery and provides such machines with a CE mark. For partly completed machines, a Declaration
of Incorporation is issued.
In order to determine all hazards associated with a product, MTU carries out a risk assessment. By imple-
menting suitable protective measures, the hazards posed to human health and the environment are reduced
or completely eliminated for all life stages in accordance with the state of the art. All important information
on residual risks and on the safe and intended use of the machine can be found in the operating manual and
other customer documents.
Integration of machinery / pressure devices / gas appliances

MTU can issue declarations of conformity and incorporation only for the scope of delivery. In order to deter-
mine possible safety-related linking between several machines / pressure devices / gas appliances, a high-
er-level risk assessment of the whole plant system is to be drawn up. The manufacturer of the complete
plant is responsible for the preparation of the higher-order risk assessment, the implementation of the high-
er-order safety concept derived from it and the Declaration of Conformity with CE mark.
Depending on the plant system and the setup of the machine, some aspects may need to be
considered:
• Internal and external explosions
• Fire
• Ventilation concept
• Heat utilization
• Biogas application
• Mechanical and electrical hazards
• Switching of the plant system, or a part thereof, to a safe state and protection against inadvertent start-up
The fulfillment of the conditions specified in this document is a prerequisite for the safe and smooth opera-
tion of the plant system.
Prior to the start of planning, an investigation into the requirements regarding official specifications has to be
carried out and any required approvals obtained. The requirements for the building also apply to the contain-
er solutions, where appropriate.
Documents to be used:
• Technical description
• Technical data sheet
• Foundation data sheet
• P&I diagram
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• Planning drawing
• Fluids and Lubricants Specifications
• Quality of safety components (→ Page 47)
MS65032/06E 2021-01 | Product Information | 5

3 Requirements for Building and Foundation
3.1 General requirements
The statics of the building must have a rating sufficient for the plant. If necessary, consult a structural engi-
neer. Structural fire protection must be accomplished in accordance with the local laws and regulations. The
foundation must be flat and such that it can safely support the weight of the engine-generator set and sys-
tem components. The weight of the engine-generator set can be obtained from the technical data sheet.
With regard to the vibrations caused by the engine-generator set, the foundation must be designed in accord-
ance 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 (→ Page 13). The building / container must have sufficient
protection against lightning strokes. The plant must be integrated in the on-site lightning protection system.
Specifications of insurance providers and authorities regarding lightning protection and fire protection must
be researched (e.g. preparation of an integrated fire-protection concept, dividing into fire sections etc.).
Important
The technical data sheet and the foundation data sheet must be observed.
Important
To be observed in protection and danger zones (flooding areas):
When installing plants in protection and danger zones (flooding areas), general locally applicable laws, di-
rectives and standards must be observed.
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6 | Requirements for Building and Foundation | MS65032/06E 2021-01

4 Room Information
4.1 Premises – Requirements
To increase the level of work safety with regard to noise emission and vibration emission, it is recommended
to install the engine-generator set and the switchgear in separate rooms, if possible. In so doing, the danger
of the control cabinets overheating will be reduced.If a dedicated switchgear room cannot be provided, the
installation site must comply with the requirements for the control cabinets delivered by MTU.
Due to the noise emission, a sound-insulating enclosure is recommended for the engine-generator set. There
must be sufficient lighting in the installation room and the room for the switchgear. The use of halogen spot-
lights 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 engine-generator set or the module is delivered by MTU as a container solution, the container must be
secured such that willful damage or unauthorized access by third parties can not occur.
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MS65032/06E 2021-01 | Room Information | 7

4.2 Installation compartment – Requirements
For safe operation of the engine-generator set, the installation compartment must be suitably arranged. Dur-
ing the planning 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 / engine-generator set as well as sufficient ventilation. The dimensions of the engine-generator set are
shown in the planning drawing. The space required for movement during operation, maintenance and repair
is also shown in the planning drawings. These dimensions required for movement must be observed in all
circumstances. In addition to the dimensions of the engine-generator set 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. Surfaces 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 possible. Ventilation ducts must be at least 0.7 m above the top edge
of the mixture cooler.
Important
Observe the planning drawing from MTU.
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 engine-generator set can be obtained
from the technical data sheet.
Series 400:
• The installation of a crane rail is recommended.
Series 4000 and 500:
• The installation of a crane rail is necessary.
Important
Observe the planning drawing from MTU 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 the installation compartment. The minimum distance required for fire protec-
tion 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 de-
tection 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). No combustible material must be de-
posited or stored in the installation compartment.
The corresponding national legislation and local regulations 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 system can not be excluded.
More detailed requirements are described in the Exhaust system chapter.
8 | Room Information | MS65032/06E 2021-01

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 alarm system to be integrated in the plant control sys-
tem is necessary. For this purpose, at least one gas warning sensor must be installed above the gas engine
in direction exhaust air. Dead corners in the installation compartment without a flow should be avoided
where possible 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 system, 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 engine-generator set (acoustic
enclosure) or acoustic boards in the installation compartment. The respective national legislation and local
regulations must be observed.
Vibrations
The engine-generator set must be mounted on insulating boards to reduce the vibration transfer to the build-
ing and foundation. The length and number of the boards to be provided depends on the size and weight of
the engine-generator set according to the planning drawing from MTU. External vibrations must not act on
the engine-generator set because this affects the natural frequency of the engine-generator set, 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 water protection regulations (e.g. VAwS - Ordinance on
Installations for the Handling of Substances Hazardous to Water and on Specialist Firms) and the WHG (Wa-
ter Resources Act). If an extended oil system is used, the tank(s) must have a double-walled design and be
equipped with a leakage indicator system. To reliably prevent the penetration of fluids and lubricants and
water-polluting substances in the water system / groundwater, local regulations and requirements (oil sepa-
rator, retaining device, leakage detection) must be observed.
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.
When installing or erecting plants in protection and danger zones, additional country-specific laws, directives
and standards must be observed.
Ambient conditions (dust, moisture)

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If control cabinets are located in the installation compartment, the ambient conditions must comply with the
design of the scwitchgear/control cabinets, (→ Page 11).
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. Since the design of the equipotential bonding system and the protective con-
ductor depends on the local mains type, details can not be discussed here. Only generally applicable infor-
mation independent 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 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. 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 regulations of the power supply company
or the safety regulations must be observed to ensure that grounding is carried out correctly.
ZEP - 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. The delivery from MTU
includes a set of "Warnings" stickers 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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4.3 Switchgear room – Requirements
A separate switchgear room cannot always be provided because some engine-generator sets feature control
cabinets that are mounted directly on the base frame. In this case, the ambient conditions specified below
also apply to the installation compartment of the engine-generator set.
The ambient conditions (dust, moisture) of the switchgear room must comply with the specifications of the
control cabinets.
For reasons of accessibility, it must be possible to open all control cabinet doors up to angles of at least
120°.
Cabinet Degree of protection Ambient temperature
MIP IP54 0 to 40 °C
MMC IP54 0 to 30 °C
ECC IP54 0 to 35 °C
HA IP54 0 to 30 °C
GLF IP2X 0 to 35 °C
Table 2: The control cabinets supplied by MTU typically meet the following requirements:
For certain projects, values may differ due to special requirements; in such cases, the deviations are indicat-
ed in the corresponding circuit diagram documents. The control cabinets are usually designed for air humidi-
ty of 50% at 40 °C and 90% at 20 °C. Corrosive or aggressive substances in the atmosphere can cause dam-
age to electrical component. Suitable precautions must therefore be taken on site to prevent a corrosive or
aggressive atmosphere in the switchgear room.
Optional air conditioning units are available for operation at higher ambient temperatures. For more detailed
information on the control cabinets, see (→ Technical Description of the Control System).
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4.4 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 performing 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 engine-generator set, 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 control valve must not exceed a certain length.
• Series 4000: Maximum length of gas hose: 3 m
• Series 400 and 500: 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 can be reached
ergonomically and are easily accessible.
• 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.
Important
Comply with the information in the operating manual and on the technical data sheet supplied by the man-
ufacturer.
Starter batteries
With Series 400, the starter batteries are installed in battery racks that are arranged next to the engine-gen-
erator set.
With Series 4000, the starter batteries are built in the base frame by means of a retainer. The wiring of the
starter(s) required for this is prepared in the factory.
With Series 500, the starter batteries are installed in battery boxes which are to be arranged underneath the
control cabinet on the floor.
Note:
• MTU uses only maintenance-free 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.
Important
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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.
Depending on the engine-generator set configuration, the batteries are already integrated in the base
frame.

5 Ventilation
5.1 Ventilation system
A ventilation system is needed for the safe use of the engine-generator set/module. Suitably qualified and
experienced planners, engineering companies or specialist companies must plan and implement appropriate
measures. Here, the conditions of the installation room and the plant system environment (geographical ori-
entation, emission sources, noise requirements and suchlike) are to be taken into consideration.
Key tasks of the ventilation system:
• Supply of combustion air to engine
• Room temperature control at a constant value
• Discharge of the cooling load of the engine and all installed equipment in the installation room
• Compliance with maximum and minimum permissible intake air temperatures, especially whenever engine
is started
• Ensuring of the required air flow rate for adequate air dilution in the event of a gas alarm (gas escaping
into installation room)
• Ensuring the required quality of the supply air, see (→ Fluids and Lubricants Specifications)
If the quality of the supply air is poor, additional measures are required to ensure an adequate air quality.
For the technical data of the engine-generator set / module and the required operating conditions (e.g. de-
rating diagram), see (→ Technical Datasheet) and (→ Technical Description).
Requirements of the ventilation system:
• Reliable supply of combustion air, independent of operating state
• Dimensioning compatible with cooling load to be discharged
• Uniform forced ventilation of the installation room to avoid heat accumulation and formation of potentially
explosive gas/air mixtures at blind spots
• Series 400 and 4000: Routing the supply air flow to the generator side (→ Figure 1)
• Series 500: Routing the supply air flow angular from above to the air filter (→ Figure 2)
• Direct discharge to outside of building
• Electrically-activated louvers
• Repair switch for fan as protection against inadvertent startup when maintenance tasks are carried out
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MS65032/06E 2021-01 | Ventilation | 13

Figure 1: Series 400 and 4000 ventilation system
A Supply air B Outlet air
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Figure 2: Series 500 ventilation system

A Supply air
14 | Ventilation | MS65032/06E 2021-01

Positioning of supply-air intake:
• Position the supply-air intake in such a way that no exhaust air can enter
• Position the supply-air intake in such a way that no foreign matter or contaminants (exhaust gases, toxic
or flammable gases, solvent vapors, dust) can enter the installation room
• Position the supply-air intake in such a way that the coolest possible air is drawn in
Compliance with the maximum and minimum permissible values:
• Room temperature control with temperatures between 25 °C and 30 °C (guiding values)
• Maximum permissible exhaust air temperature of 50 °C
• Intake air temperature for starting of engine between 10 °C and 40 °C
• Maximum permissible overpressure in room of approx. 50 Pa (no doors thrown open)
• Maximum permissible overpressure of the room-encircling surfaces
• Maximal permissible overpressure in installation room of 80 Pa (necessary for opening of doors)
• Maximal permissible overpressure of the room-enclosing surfaces
Weather guard, small-animal guard and ventilation grill to prevent:
• Injuries as contact protection
• Penetration of foreign matter, particles and dust
• Entry of any type of animal
Consideration of seasonal temperature variations (summer, winter):
• Closing of louvers for supply air and exhaust air for temperatures <10 °C
• Heating of supply air or installation room if there is risk of frost
• For mixed-air systems / air-circulation systems, the outer louvers and exhaust air louvers must be forced
open automatically, so that the three-fold air exchange in the installation room and the supply of combus-
tion air to the engine are guaranteed
Compliance with acoustic requirements:
• Use silencers in supply air and exhaust air ducts. The effect of other acoustic sources such as exhaust
stack, recooler and flow noise must be considered as well.
• Due to sound radiation from the installation compartment, acoustic paneling (e.g. double-skin acoustic in-
sulation, noise suppression coating) for the ventilation ducts and components is necessary.
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5.2 Combustion air supply
The following factors influence engine power:
• Flow rate of combustion air that can be drawn in
• Air temperature
• Air pressure (site altitude)
Refer to the current Technical Description for the required combustion air volumetric flow and the required
combustion air quantity.
Variants of combustion air supply device for engine:
• Supply via air filter directly from installation room; combustion air is provided via the ventilation system.
• Supply via air filter (as in point above) with Series 4000 air intake extension or connection to customer-
supplied devices (provided MTU has been consulted and given written approval)
• Supply via air filter directly from outside the building (provided MTU has been consulted and given written
approval)
Requirements for compressed air supply:
• The combustion air is supplied via the ventilation system in the installation room.
• Only operated with the dry-air single filters from MTU which are directly attached to the engine. Other air
filters are not to be used unless MTU has been consulted and given written approval.
• Consideration of the removal height for air-filter replacement
• Usage of filters for the supply air intakes if there is an increase in the amount of dust
• Avoidance of impermissible overpressure at intake hose or air filter; the connection must be designed as a
flow safety device
• Compliance with the minimum intake-air temperature, especially in winter
Concerning the supply of combustion air directly from outside the building, some additional requirements
apply.
Account must be taken of the filter design, which affects the engine noise level. The sound ranges of MTU
are based on measurements with the dry-type, single air filters.
Combustion air flow rate

Refer to the current Technical Description for the required combustion air volumetric flow.
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5.3 Room-air supply
There are various ventilation concepts concerning the supply of room air:
• Overpressure in the installation room
• Underpressure in the installation room
• System with supply air and exhaust air fans (recommendation of MTU)
• Mixed air system (with circulation air share)
• Ventilation system with variable volumetric flow rate
• Ventilation system with heat recovery (risk assessment required)
For a ventilation system with heat recovery, only supply air is drawn in. The ventilation system is run in pure
air circulation mode and the waste heat discharged via coolers. With such an arrangement, a separate risk
assessment always has to be carried out by the system planner / owner. It must be ascertained that no gas
can enrich in the installation room due to gas leaks. The gas has to be discharged safely outside the building.
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MS65032/06E 2021-01 | Ventilation | 17

5.4 Room air flow rate
The minimum amount of supply air needed to cool the installation room is indicated on the technical data
sheet. For extreme installation conditions (such as non-standard air pressure, site altitude, etc.), the air re-
quired for cooling the installation room can be estimated using the following formula:
CS
V° N = VN + V° LN
p0,Lx cpx ΔT
Term Description
Q [kW] Quantity of heat to be removed; equal to sum
of:
• Radiant heat and convective heat of engine (indi-
cated in TD)
• Generator loss (difference between engine out-
put and generator output)
• Radiant heat of auxiliary drives (approx. 1% of en-
gine output)
• Radiant heat of plant system components for uti-
lization of heat (exhaust gas heat exchanger,
pumps, plate heat exchanger, etc.), amounting to
approx. 1% of useful heat
p0,L Standard air density 1.293 kg/m³ at 1.013 bar
0 °C
kJ Specific heat capacity of air 1.001 kj / kg K at
cp [ ] 1.013 bar 0 °C
kg K
ΔT Temperature difference (expressed in K) between
drawn-in and discharged air
V° N Required air flow rate under normal conditions (ex-
pressed in Nm³/s and indicated in the TD)
V° LN Combustion-air flow rate under normal conditions
(expressed in m³ N / h and indicated in the TD)
V° B Required operation-air flow rate at installation loca-
tion (expressed in m³ / s or m³ / h)
T [°C] Maximum air temperature in installation room
p [bar] Air pressure in installation room
Table 3: Nomenclature with descriptions for room air flow rate

The following equation is used for converting from standard cubic meters to operation cubic meters at a tem-
perature of X °C:
273 + T 1.013 bar
VB = VN [ ]x
273 p
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18 | Ventilation | MS65032/06E 2021-01

5.5 Safety requirements for the ventilation system
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.
Important
Depending on the ventilation concept, the use of an ignition source-free fan wheel in the exhaust air may
be necessary.
This means:
• Adequate fresh air supply and its mixing during operation in the installation compartment must be guaran-
teed. Accumulation of operation-related, unavoidable leaks on vibrating components with no permanent
technical sealing must be prevented by the ventilation.
• Installation of a gas detector for CH4 detection in the event of serious leaks
• With circulation air systems, the share of fresh air must be at least 25%.
• With circulation air systems, the operator must ensure that the rooms are monitored for hazardous CO2
or CO2 concentrations. Depending on the specifics of the relevant plant, the use of a mobile CO / CO2
detector can be helpful when the operator conducts routine checks or maintenance work, in particular if
exhaust pipes are routed through rooms without forced ventilation, or where circulation ventilation sys-
tems are used.
• To prevent the formation of an ignitable gas-air mixture in dead areas, the installation compartment must
be flushed uniformly. If there are dead areas in the installation room 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.
Series 400
For naturally-aspirated engines in the 400 series, the installation of a gas detector is not necessary because
TIM-ID: 0000062669 - 004
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.
MS65032/06E 2021-01 | Ventilation | 19

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.
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20 | Ventilation | MS65032/06E 2021-01

6 Gas System
6.1 Customer-provided gas system
Assembly and connection work on gas-carrying systems must only be carried out by a certified and author-
ized gas specialist company with qualified personnel.
Gas system requirements in Germany are defined by the technical regulations of the DVGW (German Techni-
cal and Scientific Association for Gas and Water).
In the country of installation, it may be necessary to observe other country-specific requirements of the gas
installation and qualifications of the specialist company.
Local authorities may require further safety devices in addition to the main shut-off cock, e.g. safety shut-off
valves with integrated temperature monitoring (SAV), or thermal shut-off devices (TAE) others.
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MS65032/06E 2021-01 | Gas System | 21

6.2 Requirements for the customer-provided gas system
Requirements
• The connection line must have a manual shut-off valve outside the installation room. This must be easy to
reach in the event of danger.
• For each engine-generator set, a connecting gas line with shut-off valve needs to be provided by the cus-
tomer
• Potentially explosive mixtures must not reach generally accessible areas, neighboring rooms or the vicinity
of ignition sources.
• Fuel lines must be laid out in such a way that they are not subject to stress or abrasion and are not bent.
• Large temperature differences between the fuel line and the installation room result in a relatively high
degree of condensation within the fuel line. The engine will be pressurized with water and can be damaged
as a consequence. Such a situation can be avoided by correct installation of the fuel line in the installation
room. If necessary, a trace heating system is to be used. If a relatively high degree of condensation can
still be expected, it is recommended to fit a manual drain cock at the lowest point of the gas line and to
drain the line at regular intervals.
• The permissible operating pressures in the gas train are indicated on the technical data sheet. If the pres-
sure in the customer-provided fuel line is beyond the permissible range of pressures, a gas reduction sta-
tion is to be installed.
• The venting line of the safety exhaust valve in the gas reduction station must safely convey the gas to the
outside of the building.
Additional requirements with use of biogas

When biogas is used, the gas system from the fermenter to the machine must be hermetically sealed so that
no ambient air can be drawn in. For additional monitoring systems, such as underpressure and overpressure,
leaks, etc., separate inputs can be provided in the MMC controller.
In addition, the following points must be checked:
• Monitoring of gas leaks and insufficient gas in the biogas compressor
• Positioning of the evaluation unit of the gas detector outside the danger area
• Use of separating barriers when positioning the safety sensors in protection zones
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22 | Gas System | MS65032/06E 2021-01

6.3 Required gas quality
The gas quality must comply with the Fluids and Lubricants Specifications of MTU.
Important
Observe the Fluids and Lubricants Specifications.
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MS65032/06E 2021-01 | Gas System | 23

7 Coolant Circuit, General
7.1 Coolant circuits
The coolant circuits are to be planned and designed according to customer requirements by a planning agen-
cy or a specialist company.
All data relevant to the planning and design of the system can be found in the documentation of MTU.
The engine-generator set can be operated as a pure electricity generator (without utilization of heat), as an
engine-generator set with engine coolant heat extraction or with additional utilization of exhaust gas heat.
For all applications, a mixture coolant circuit (low-temperature circuit) and an engine coolant circuit (high-
temperature circuit) must be available. For both naturally aspirated engines and supercharged Series 400
engines, a hot cooling system is optionally available. Here, heat is transferred directly to the customer’s
heating system via a separate oil heat exchanger. For plants for which heat is not taken from the customer’s
network, an emergency cooling water circuit (engine coolant circuit or heating water circuit) must be provid-
ed. A recooler must be provided for the mixture coolant circuit in all cases. The waste heat is discharged to
the outside via the recooler of the emergency coolant circuit.
Discharging waste heat:
• For pure electricity-generating units, an emergency cooler is always required to dissipate engine heat.
• For current-controlled compact cogeneration modules, an emergency cooler is normally used to avoid a
reduction in electric power or a shutdown due to fluctuations in the heat dissipation rate.
• For purely heat-controlled compact cogeneration modules, an emergency cooler can be used to compen-
sate for process fluctuations. If there is no or a relatively low heat requirement, the power is shut off or
reduced in the case of purely heat-controlled plant systems.
• An emergency cooler is always required to dissipate mixture coolant heat.
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24 | Coolant Circuit, General | MS65032/06E 2021-01

7.2 Application as pure electricity generator
Mixture coolant circuit
Series 4000
• The mixture cooler for Series 4000 engines is always a two-stage design. In the turbocharger, the gas/air
mixture is compressed and thereby heated. In the first stage, the mixture is cooled via the engine coolant.
In the second stage, the mixture is cooled via a separate low-temperature cooling circuit. The heat is dis-
charged to the outside of the building via the recooler.
Series 400
• On Series 400 engines with exhaust turbocharger, the mixture cooler can be a single-stage or two-stage
type. In the turbocharger, the gas/air mixture is compressed and thereby heated. The heat is discharged
to the outside of the building via the recooler.
Series 500
• On Series 500 engines, the mixture cooler can be a single-stage or two-stage type. In the turbocharger,
the gas/air mixture is compressed and thereby heated. The heat is dissipated to the outside of the build-
ing via the recooler.
Engine coolant circuit

In the engine coolant circuit, the engine coolant has to be recooled. For current-controlled operation, either
the heat is to be dissipated via the customer’s network or else an additional emergency coolant circuit must
be provided.
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MS65032/06E 2021-01 | Coolant Circuit, General | 25

7.3 Application with heat recovery
The interface to the customer, i.e. the point of separation of the hydraulic systems (coolant circuit and cus-
tomer's heating water system) can vary depending on the specific application:
• Plate-core heat exchanger is the point of heat transfer
• Plate-core heat exchanger and exhaust gas heat exchanger connected in series form the point of heat
transfer
Mixture coolant circuit with two-stage mixture cooling (all engine series)
The heat produced in the first stage of the mixture cooler (high-temperature circuit) is transferred to the cus-
tomer’s heating system.
Options for transferring to the customer's heating system:
• Transfer to the customer’s heating system via the engine coolant circuit and the plate-core heat exchang-
er
• Direct transfer to the customer’s heating system
Depending on the means of transfer, the thermal efficiency or the supply temperature can be increased.
The mixture coolant from the second stage (low-temperature circuit) can not usually be used for the heating
water circuit. The heat has to be discharged to the outside of the building via the recooler.
Single-stage mixture cooling (Series 400)

The heat produced in the single-stage mixture cooler can either be transferred to the customer’s heating wa-
ter circuit or discharged to the outside of the building via the recooler.
Engine coolant circuit

In the engine coolant circuit, the heat is transferred to the customer’s heating system via a plate-core heat
exchanger. If the heat is not constantly removed by the customer’s heating system, an additional emergency
coolant circuit or a buffer reservoir must be provided.
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7.4 Application with exhaust gas heat recovery
By using an exhaust gas heat exchanger, the heat contained in the exhaust gas can be rendered usable for
the customer. However, in this case as well an additional emergency coolant circuit or a buffer reservoir is
required if the heat is not constantly removed by the customer’s heating system.
The maximum permissible pressures and temperatures are indicated on the technical data sheet and on the
piping & instrumentation diagram.
The pressures and temperatures indicated on the technical data sheet and on the piping & instrumentation
diagram must under no circumstances be exceeded.
Important
The following requirements are to be noted:
• Technical data sheet (pressure and temperature specifications)
• P&I diagram
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7.5 Coolant circuits – Design
With regard to the design of coolant circuits, the following generally applies:
• One or several filling or drainage points are to be provided at the lowest point of the cooling system. This
will ensure that no residual cooling water remains in the cooling system after this has been drained.
• One or several venting points are to be provided at the highest point of the cooling system.
• All openings at manually-controlled filling and venting points, along with other openings in the coolant cir-
cuits, must be closed off tightly such that they can only be opened again with a tool.
• Options for the hydraulic separation of the coolant-conveying systems must be provided.
• Coolant circuits are to be designed as closed overpressure systems.
• The closed coolant circuits must each be secured by at least one safety valve to avoid exceeding the max-
imum permissible operating pressure. At the safety valve, an exhaust pipe must be attached. Exhaust
pipes are to be installed such that no person is at risk from scalding.
• The penetration of water-polluting substances into the water supply or groundwater must be reliably pre-
vented (Water Resources Act).
• The coolant circuits must all be equipped with diaphragm-type expansion tanks, which are designed ac-
cording to the volume of the coolant circuits.
• The conveyance volume of the pumps must be in line with the values indicated on the technical data
sheet.
• Concerning the design of the coolant circuit, the temperatures and pressures indicated on the technical
data sheet must be taken into account.
• Pressure, temperature and low-water monitoring devices are to be provided.
With regard to the design of coolant circuits, the following applies to Series 500:
• Depending on the design version, coolant pumps and pressure-equilizing reservoirs are installed on the
engine-generator set. It must be checked whether the pressure margin of the coolant pumps for the pipe-
work in the building and the static head are sufficient.
The requirements for safety devices and for the water quality for plate-core heat exchangers and exhaust gas
heat exchangers are given in the technical documents of the respective manufacturers and must be com-
plied with.
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Figure 3: Exemplary schematic drawing
1 Mixture cooler, HT circuit 7 Expansion tank (engine 13 Cooler (mixture coolant cir-
2 Oil cooler coolant circuit) cuit)
3 Safety valve (engine coolant 8 Circulating pump (engine 14 Expansion tank (mixture
circuit) coolant circuit) coolant circuit)
4 Restrictor valve (engine 9 Mixture cooler, LT circuit 15 Circulating pump (mixture
coolant circuit) 10 Safety valve coolant circuit)
5 Plate-core heat exchanger 11 3-way valve with limit 16 Throttle (mixture coolant
or fan cooler switch circuit)
6 Warm-up thermostat 12 Aerator and vent
For the actual design of the coolant circuit, see (→ Piping & instrumentation diagram).
If the planning and design are carried out by MTU, all components, assemblies and safety parts will be sup-
plied by MTU. The coolant circuits must be designed according to the supplied piping & instrumentation dia-
gram and the safety functions integrated according to the safety concept of MTU.
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7.6 Emergency recooler
In addition to the stated requirements of the engine coolant circuits, the following applies to the emergency
coolant circuit: If the return flow temperature from the customer’s heating system is too high, an adequate
amount of recooling via the emergency coolant circuit has to be guaranteed. The emergency coolant circuit
must therefore be equipped with devices which regulate the emergency recooler, pumps and valves in such a
way that a suitable engine coolant temperature at the inlet of the engine is achieved.
Installation recommendations for recooler:
• Recooler must be mounted on a level, horizontal surface in the open air.
• Dirt must not be sucked into the recooler from below.
• A concrete slab or concrete covering is recommended.
• The waste heat must be able to rise upward unobstructed.
• It must be ensured that no hot air can be drawn in by neighboring coolers.
• If set up near a wall, sunlight can be reflected by the wall onto the recooler. This leads to warm air being
drawn in and the heat removal requirement no longer being met.
• The specifications for minimum distances to walls and neighboring coolers must therefore be taken into
account.
• The maximum permissible noise emission values must be taken into consideration when selecting the in-
stallation locations and the recoolers.
The following applies to the optional emergency recooler with Series 500:
• Emergency cooling is designed through a branch in the engine cooling circuit. It must be checked whether
the pressure margin of the coolant pumps for the pipework in the building is sufficient. A second pump is
required should the pressure requirements exceed the pressure margin of the pump.
• If the emergency recooler has a static head > 10 m, the hydraulic system must be checked.
Important
Observe the technical data sheet.
Plate-core heat exchanger

Devices must be provided in front of and behind the plate-core heat exchanger (temperature sensors, FC
pumps, return flow boost with 3-way valve). Such devices will help to ensure that the engine is sufficiently
cooled and the coolant is maintained at a constant temperature at the inlet of the engine.
Required water quality

The water quality must comply with the Fluids and Lubricants Specifications of MTU. Here, the requirements
for the most sensitive components take precedence. If the required water quality can not be guaranteed, a
specialist company for the treatment of circulating water must define and implement suitable treatment
measures.
Important
Observe the Fluids and Lubricants Specifications.
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8 Connection Regulations
8.1 Pipes and connections
When operating the engine-generator set / heat recovery module / CHP, high pressures and temperatures
are generated in the coolant circuits. Pipelines must therefore withstand the expected mechanical, thermal
and chemical stresses.
Due to the vibration generated by the engine, the customer-provided systems must not be rigidly connected
‒ otherwise there is a risk of lines breaking and hot liquids escaping. Flexible hose lines or bellows must
always be used as intermediate pieces. These also reduce the amount of vibration transferred to the connec-
tion systems. The support of the piping of the plant shall be designed in such a way that the bellows of the
generator sets are not exposed to mechanical forces.
piping & instrumentation diagram. They must not be exceeded under any circumstances. The components of
the exhaust system must be designed to withstand a bursting pressure (pü) of at least 1 bar.
The expansion and material stresses that arise as a result of the high temperatures and pressures generated
must be taken into account when designing the oil system, the exhaust system and coolant circuits. Conse-
quently, a sufficient number of bellows as well as loosening and fastening points are to be provided when
laying out the piping.
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Figure 4: Loosening and fastening points of the exhaust line

1 Bellows 3 Fixed attachment point
2 Silencer 4 Loose attachment point
(piping)
Important
Observe the technical data sheet and piping & instrumentation diagram of MTU.
The customer’s connection systems must be designed using suitable materials:
MS65032/06E 2021-01 | Connection Regulations | 31

Medium/Line(s) Case Piping material
Natural gas Galvanized steel; steel or high-
grade steel between gas train and
engine
Biogas, sewage gas, landfill gas, High-grade steel
gas accompanying crude oil
Water Engine coolant circuit, mixture Steel; high-quality materials possi-
coolant circuit, heating water cir- bly also necessary depending on
cuit, emergency coolant circuit water quality
Lube oil, hot engine oil circulation High-grade steel
lines
Fresh-oil filling line and waste oil Steel, high-grade steel
lines
Exhaust pipework Operation with natural gas, opera- High-grade steel
tion with biogas, sewage gas,
landfill gas, gas accompanying
crude oil upstream of catalytic
converter
Condensate line Acidic content High-grade steel
Other Steel, copper, galvanized steel
Table 4: Materials for customer-provided connection systems

For oil and coolant circuits, the following information applies:
• The pipes and hoses used must contain neither zinc nor copper.
• Zinc in steel or lines has a corrosive effect when exposed to continuously high water temperatures.
• Zinc and copper have a damaging effect on the additives of the engine lube oil and make the results of the
oil analysis inaccurate. The oil service life will thus be reduced.
The following applies to engine coolant, hot water and heating water pipes:
• For pipe dimensioning, a water velocity of 2 m/s should be assumed.
• Provide flexible connections at the interfaces between the gas engine-generator set and the on-site water
system. Provide suitable filters to keep the hot water system clean.
• Monitoring must be provided in accordance with country-specific regulations (e.g. max. pressure; max.
temperature; max. flow rate). The pipe system must be cleaned before putting it into operation.
• A leak test must be carried out (test certificate). It is recommended to contract a suitable specialist com-
pany to build the water system.
Important
Provide sufficient space for the insulation of the water pipes.
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32 | Connection Regulations | MS65032/06E 2021-01

9 Lube Oil System, Lube Oil Circuit
9.1 Extended lube oil system
For continuous operation, automatic refilling of lube oil is required.
MTU supplies the complete tank system for the extended lube oil system. If the tank system is not included
in the MTU scope of delivery, the system planner must prepare a higher-level risk assessment.
Capacity
Adequate dimensioning of the fresh-oil and waste-oil tanks ensures that the filling and draining processes are
limited to two or three times per year. The required tank capacity can be determined from the information on
the technical data sheet. MTU supplies double tanks as standard with an overflow in the partition wall. If two
single tanks are used, a connection between the two tanks must be established with a communicating line.
The following additional volumes with oil bleed system are recommended:
Additional capacity with an oil bleed system for Series 4000

Series 4000
Engine model Tank capacity
8V4000L32 / 33 / 64 2 tanks, each with a capacity of 1000 l
Table 5: Additional capacity with an oil bleed system for Series 4000
Additional capacity with oil bleed system, for Series 400

Series 400
All engine types 2 tanks, each with a capacity of 1000 l
Table 6: Additional capacity with oil bleed system, for Series 400
Additional volume for Series 500

Series 500
All engine types Oil volume expansion tank in base frame (approx.
200 liters depending on engine-generator set) with
automatic replenishment system
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All engine types 2 tanks with 1000 liters each with manual filling via
button on the control unit
Table 7: Additional volume for Series 500
General requirements of the installation compartment

With Series 4000, the base frame features an assembly to connect an extended oil system.
The required space can be determined from the technical documents of the tank manufacturer.
If tank filling from oil barrels is provided, catch basins must be used for oil barrels.
MS65032/06E 2021-01 | Lube Oil System, Lube Oil Circuit | 33

A version with deep tanks is not provided as standard. If deep tanks are used, consultation with MTU is re-
quired.
Important
Observe local specifications and environmental regulations.
Space requirement
Tank Volume Volume Length Width Total Height Total Weight
type 100% 95% width height
Designa- Liter Liter mm mm mm mm mm kg
tion
KTD 950 990 930 1000 750 760 1500 1950 450
KTD 2000 2040 1930 1500 1000 1010 1500 1950 680
Table 8: Dimensions and weight

Dimensions and weights can be obtained from the functional description / technical description.
Ambient conditions
Temperature ranges see (→ Technical data sheet)
Maximum air humidity 75%
The tank system must not be installed and operated in a corrosive or aggressive atmosphere. The tank sys-
tem must be installed and operated exclusively in dust-free, dry rooms.
For more detailed information, refer to the technical documentation of the manufacturer of the tank system.
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34 | Lube Oil System, Lube Oil Circuit | MS65032/06E 2021-01

10 Exhaust System
10.1 Exhaust system
The entire exhaust system including all its components has to be planned and designed by a specialist com-
pany.
piping & instrumentation diagram. They must not be exceeded under any circumstances. The exhaust gas
flow rate must remain in the range 20 to 25 m/s. In this case, flow-induced noise formation has to be taken
into account.
The complete exhaust system including all installed equipment, such as silencer, catalytic converter and heat
exchanger, must be designed so that it is leak-tight and resistant to corrosion and pressure. Heat- and tem-
perature-resistant screws and non-asbestos seals must be used.
Exhaust back pressure

Exceeding of the permissible exhaust back pressure will have an adverse effect with regard to the perform-
ance, the fuel consumption and the thermal load on the engine. The maximum permissible exhaust back
pressure must therefore not be exceeded.
Important
The maximum permissible exhaust back pressure is indicated on the technical data sheet.
Flow resistance
When selecting the components, the flow resistances must be noted and a resistance calculation for the ex-
haust system must be performed from the turbocharger to the outside of the building. The local require-
ments for noise emission also have to be taken into account.
Required nominal width of exhaust line

The nominal width of the exhaust line is determined by the following factors:
• Exhaust gas flow rate
• Maximum permissible exhaust back pressure
• Noise requirements (guideline value of flow velocity approx. 20 to 25 m/s)
• Type of line layout (pipe length, radii of curvature, fitting of silencers, catalytic converters, exhaust gas
heat exchangers, bypass flap)
Resistance to bursting
The piping of the plant and the associated components must be designed to withstand a bursting pressure
(pü) of at least 1 bar (downstream of exhaust gas turbocharger). Outside Germany, the required bursting re-
sistance may differ according to the respective applicable requirements.
The bursting resistance can also vary due to differences in piping geometry, jumps in cross-sectional area
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values, elbows and SCR catalytic converters. The bursting resistance therefore has to be determined accord-
ing to the line layout. The exhaust gas heat exchanger must only be integrated in the engine cooling circuit
following consultation with MTU.
MS65032/06E 2021-01 | Exhaust System | 35

Additional requirements
• With the planning and design of the exhaust system, it has to be ensured that no exhaust gas can be
drawn in by air-conditioning systems.
• No moisture must reach the engine via the exhaust gas line. The exhaust outlet is to be designed accord-
ingly.
• A condensate drainage device is to be fitted in the exhaust line.
• To prevent exhaust gas escaping from the condensate drainage device, a siphon with a suitably large wa-
ter trap depth or a condensate separator is to be fitted. Additionally, a suitable and approved condensate
neutralization system can be installed.
• The design must guarantee favorable flow properties.
• Exhaust gas measurement points for measuring emissions downstream of the engine, downstream of the
catalytic converter or upstream of the entry to the chimney are to be set up. These must be easily accessi-
ble for performing measurements.
• The exhaust system must be leak-tight, e.g. through welded pipes. Plug connections are not permitted.
• Flanged joints (e.g. for silencers or bellows) must have heat-resistant bolts.
• When selecting the materials for the exhaust components (e.g. exhaust pipe, gaskets, connecting pieces,
etc.), it must be taken into account that temperatures of up to 650 °C can occur.
Condensate
Any condensate from the exhaust gas heat exchanger, silencer, exhaust pipe, etc. must be drained and dis-
posed of in a suitable manner.
The condensate drain must be arranged on site at the lowest points of the exhaust pipe, the exhaust gas
heat exchanger and the silencer.
All drains must be routed into a water seal. The water seal must be sufficiently dimensioned so that no ex-
haust gas can escape into the installation compartment. Condensate lines must not be merged.
Multi-engine plants
In plants with several engine-generator sets, the exhaust systems must not be combined.
Structural requirements
Chimney
• The chimney should allow the exhaust gas to flow unimpeded into the atmosphere. Here, the ambient con-
ditions also need to be taken into account.
• The exhaust outlet is to be fitted with small-animal guards.
• Wall bushings must be insulated against high exhaust gas temperatures.
• If necessary, a wind absorber must be provided at the chimney.
• One exhaust line and one chimney are recommended for each engine.
Important
For some plants with several engines, it may be necessary to design a common exhaust line for structural
reasons. In such a case, each engine must be equipped with a suitable exhaust flap. This then ensures that
no exhaust gases from the other engines reach the exhaust gas section of a stationary engine.
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Space requirement for insulation

The temperatures of the surfaces should not exceed 60 °C if possible. The surface temperature that is spe-
cifically required can be determined from EN ISO 13732. If hot surfaces can not be sufficiently insulated,
suitable fixed protective separators providing protection against contact must be provided. In this case, the
space required must be considered.
36 | Exhaust System | MS65032/06E 2021-01

Figure 5: Example of exhaust system with space requirement for insulation
1 Exhaust outlet 5 Pressure line 9 Silencer
2 Catalytic converter 6 Pressure line 10 Exhaust gas heat exchanger
3 Heating water inlet 7 Heating water inlet
4 Exhaust line 8 Heating water outlet
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10.2 Exhaust line
The exhaust line is to be designed so that it is fitted with bellows and has loosening and fastening points.
Flanged joints must have heat-resistant bolts. Plug connections are not permitted in the exhaust line.
To ensure that no impermissible forces induced by thermal expansion of the exhaust line act on the engine
via the bellows, a fastening point (for fastening to building) just beyond the bellows must be provided. Other
bellows are to be fitted as need be, according to where else thermal expansion may occur.
Figure 6: Bellows
1 Cold state (assembly tem- 3 Engine operation, warm op-
perature), prior to installa- erating status
tion (unloaded state) 4 3 clamping pieces serving
2 Cold state (installation tem- as installation aids and
perature), installed state spread around the periphery
(pre-stressed bellows) (e.g. pipe, wooden pallet)
The thermal expansion of exhaust pipes is indicated on the following diagram.
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Figure 7: Diagram, thermal expansion of exhaust pipes
1 Thermal expansion (in mm / 2 Austenitic steel (1.4541) 3 Ferritic steel
m)
Diagram for determining the thermal expansion of exhaust pipes according to temperature. Temperature dif-
ference between 20 °C and maximum exhaust gas temperature
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10.3 Exhaust silencer
To reduce the noise emission, an exhaust silencer has to be installed. Local laws and regulations must be
observed. To reduce the engine exhaust gas noises to the respective permissible emission limit values, pas-
sive silencer systems are usually used. Passive silencer systems reduce the individual frequency values ac-
cording to absorption and reflection principles. Depending on the permissible sound pressure level, it may be
necessary to fit more silencers (one behind the other). The design has to ensure that the maximum permissi-
ble exhaust back pressure is not exceeded. The required information for designing the exhaust silencer can
be found on the technical data sheet.
To avoid the risk of contact with hot surfaces, the exhaust silencer should not be located near any of the
spaces set aside for operation, maintenance and servicing. If this is not possible for spatial reasons, a fixed
protective separator must be fitted around the exhaust silencer.
Important
The required information for designing the exhaust silencer can be found on the technical data sheet.
TIM-ID: 0000062697 - 003

10.4 Catalytic converter
The utilization of a catalytic converter to reduce the exhaust gases produced during operation can be neces-
sary due to official regulations and national legislation. The dependence of pollutant emission on air-fuel ratio
means that various pollutant-reduction processes are required. For naturally aspirated engines, a 3-way cata-
lytic converter is used, and for lean-burn engines, an oxidation catalyst. For additional reduction of NOx emis-
sions with lean engines, SCR catalytic converters (Selective Catalytic Reduction) can be used. The reducing
agent (urea solution with an urea concentration of 32.5 %) in such catalysts reduces the nitrogen oxide emis-
sions.
3-way catalytic converter and oxidation catalyst

For an optimal conversion of pollutant gases by the catalytic converter, high temperatures are necessary.
The catalytic converter must be therefore be installed near the engine:
• Upstream of the exhaust silencer
• Upstream of the optional exhaust gas heat exchanger or in the front head of the exhaust heat exchanger
Important
The pipes before the catalytic converter must be made of stainless, scale-free steel.
The catalytic converter must be easily accessible for removal purposes, since it must be replaced regularly
according to the specifications in the Maintenance Schedule. The surface temperature of the catalytic con-
verter must not exceed 650 °C or 700 °C. The temperature therefore has to be monitored inside the catalyt-
ic converter or directly downstream of it. To protect the catalytic converter, the engine must be shut down
immediately if the permissible maximum value is exceeded. The converter can be installed in the exhaust
line, either in a separate housing or in the front head of the silencer or the exhaust heat exchanger.
SCR catalytic converter

To ensure optimum pollutant conversion or to prevent premature aging of the catalytic converter elements,
depending on the selected catalytic converter type the exhaust gas temperature must be between 350 °C
and 500 °C.
The catalytic converter must be therefore be installed near the engine:
• Upstream of the exhaust according or downstream of the reflection silencer
• Upstream of the exhaust heat exchanger
Important
The pipes before the catalytic converter must be made of stainless, scale-free steel.
The following aspects must be taken into account for SCR systems designed for separate installation (for
Series 4000 and 500) as early as in the project planning phase :
• Space requirements of the catalytic converter plus sufficient length of the mixer section (dimensions de-
pending on exhaust limit values and machine type)
• Space requirements for necessary additional systems such as control cabinet, dosing system, compres-
sor, reducing agent provision and storage
• Easy access for disassembly of the catalytic converter or the replacement of the catalytic converter ele-
TIM-ID: 0000062714 - 005
ments, including storage space for the catalytic converter elements (depending on the NOx limit value and
method of operation, every 1 to 2 years)
• Easy access to injector nozzle, sensors and pumps (maintenance approx. every 6 months)
• Signal inputs for shutting down the engine in case of fault messages can be provided (e.g. overshooting
permissible temperatures)
To prevent destruction of the SCR catalytic converter housing in the event of a deflagration in the exhaust
system, the bursting resistance of the catalytic converter housing and the design of the exhaust pipework
must be checked to determine whether an additional pressure relief valve is necessary.

Storage of reducing agent
For the reducing agent requirements, see Fluids and Lubricants Specifications.
Materials in direct contact with the reducing agent must be free of nonferrous metal and must not be sus-
ceptible to corrosion. The respective environmental specifications must be observed during the design.
The dimensions and design of the storage tank are based on the method of operation of the plant and the
existing space. Storage of the reducing agent in the engine room is not recommended because the prevailing
temperatures accelerate decomposition.
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10.5 Exhaust gas heat exchanger
With a heat exchanger (waste heat boiler or water boiler), the exhaust gas heat can reused. The required
information for designing the exhaust heat exchanger can be found on the technical data sheet of MTU and
in the manufacturer’s documentation.
The exhaust gas heat exchanger can be mounted on the floor or suspended from the ceiling. Allowance must
be made for an additional space (circle of 1 m in radius) around the heat exchanger for the carrying out of
monitoring and maintenance tasks. Servicing and maintenance ports must be easily accessible at all times. If
the exhaust gas heat exchanger is suspended from the ceiling, a suitable climbing aid has to be provided.
On Series 400 modules, the exhaust gas heat exchanger is already integrated in the base frame.
On Series 500 modules, the exhaust gas heat exchanger of is either built in the base frame or provided on
site - depending on the size of the units and the application.
To prevent exhaust gas escaping from the condensate drainage device, a siphon with a suitably large water
trap depth or a condensate separator has to be fitted. Safety devices for the monitoring of temperature and
pressure must be provided.
The maximum permissible system pressure indicated on the technical data sheet must be complied with.
This applies particularly to cases where, for structural reasons, height differences or a large distance be-
tween the engine-generator set and the cooling system have to be compensated for. In conjunction with the
heat recovery module, the installation height of the exhaust gas heat exchanger must not exceed 8 m (meas-
ured from lowest point of the engine coolant water circuit to highest point of engine coolant circuit). The
exhaust gas heat exchanger must be equipped with suitable safety devices, which reliably prevent exceed-
ing/undershooting the permissible operational maximum/minimum values for temperature and pressure. If
requested by the customer, MTU will deliver an exhaust gas heat exchanger with safety equipment that is
designed according to the customer’s system.
Important
The required information for designing the exhaust silencer can be found on the technical data sheet.
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11 Insulation
11.1 Insulation
If possible, a surface temperature of 60 °C should not be exceeded.
Design and requirements
• Refer to EN ISO 13732 to determine the surface temperature requirement for the given application.
• The surface temperature determines the thickness and heat resistance of the insulating material.
• There must be space available for fitting the insulation, with the specified minimum distances between
insulated objects taken into account.
• Fittings and instruments for maintenance and display must be easily accessible after the insulation has
been fitted.
• Removable insulation caps or jackets are required for maintenance ports and flanged connections.
• For reasons of fire protection, the insulation of the exhaust system must be provided with fire-resistant
jacketing.
• The insulation material used must comply with the requirements to health and environmental protection.
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12 Control
12.1 Safety functions and protective circuits
Depending on the scope of delivery, the control components of MTU include safety functions and protective
circuits that comply with the standard DIN EN ISO 13849-1 (Safety of Machinery – Safety-Related Parts of
Control Systems).
DIN EN ISO 13849-1 provides safety requirements and a guideline for the principles for designing and inte-
grating safety-related components of control systems. It also includes aspects of software development. For
these control system components, characteristics, including the performance levels required for designing
the corresponding safety functions, are defined.
The standard must be applied to control systems of all types of machines under the terms of the Machinery
Directive. It does not define which safety function or performance level is used for a particular case. Have a
planning agency or a suitably qualified specialist company carry out the planning with regard to the peripher-
al systems (coolant system, oil system, exhaust system and ventilation system). The higher-level risk assess-
ment for the whole plant may make further safety functions necessary. In accordance with the customer's
risk assessment or safety concept, the safety components in the area of responsibility of the customer must
also have a corresponding component quality.
Safety component or safety function describe components and functions that are not necessary for machine
operation but which are related exclusively to safety aspects.
Abbreviation Meaning
SF Safety function
SISTEMA Software Assistant of the DGUV (German Statutory Accident Insurance) for
documentation and evaluation of safety functions and components
MTTFd Component reliability (average time to a dangerous failure), (MTTFd in
years)
B10d Number of cycles until 10% of the components fail resulting in a danger
(B10d in cycles)
Redundancy Presence of several equivalent resources
Diversity Use of components from different manufacturers
SIL Safety Integrated Level (classification in accordance with standard series
DIN EN 61508 or 61511)
PL Performance Level (classification in accordance with standard DIN EN ISO
13849)
Delivery without MMC controller

If the engine-generator set is delivered only with the MTU interface panel (MIP) for engine control, then the
delivery constitutes a partly completed machine. The MIP control cabinet represents the interface to the cus-
tomer’s module controller. The manufacturer of the whole plant system is responsible for the specification
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and realization of the safety functions and protective circuits in the customer’s module controller.
Delivery with optional MTU module control (MMC controller)

If the plant is delivered with an optional MTU module control (MMC controller), the safety functions and pro-
tective circuits are included in the controller according to the safety concept of MTU (corresponding to the
scope of delivery). Concerning the safety components, the component quality guideline of MTU must be ob-
served (→ Page 47).
The following documents are to be complied with:
• Safety concept of MTU
MS65032/06E 2021-01 | Control | 45

The ventilation system, gas alarm system, and fire alarm system have to be integrated in the MMC controller
according to the specifications set out in the safety concept of MTU and the "Ventilation" chapter.
Manual emergency-stop button and customer-provided safety transmitter

In the MMC control cabinet, additional inputs are provided for a manual emergency-stop button and a safety
transmitter supplied by the customer. Regarding the required inputs, adaptations are made according to the
project. Some inputs are provided as standard according to the series and are indicated in the circuit dia-
grams.
Safe shutdown
Prior to carrying out any maintenance tasks, the ventilation system and all auxiliary drive units have to be
safely shut down in a suitable manner and secured against inadvertent start-up (via a lockable main switch /
repair switch).
Flashing horn
An acoustic and optical warning device (flashing horn) is to be installed for fire and gas alarms. This warning
device should be set up in an easily visible place outside the installation room. The precise number of flash-
ing horns is dependent on the local conditions and requirements.
Flashing horns are offered by MTU as optional equipment.
Important
Local regulations are to be complied with.
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46 | Control | MS65032/06E 2021-01

12.2 Quality of safety components
The following basic requirements apply:
Safety components must be suitable for the ambient conditions (temperature, air humidity, air pressure, site
altitude etc.) and used for the purpose described in the manufacturer's specifications.
The selected IP protection class for electric components must be suitable for the ambient conditions. Safe-
guards that protect against pressure and temperature must be suitable for the operating pressures, operat-
ing temperatures and contact media named in the Technical Data.
Parameters preset by MTU ex works must not be changed.
Important
The following must be observed:
• Technical data sheet (pressure and temperature specifications)
• P&I diagram
Important
• This chapter cites the certificates required in the European economic area. Further country-specific re-
quirements may also have to be observed and test certificates obtained
• For countries outside the European economic area, required certificates and test certificates must be
taken into consideration
Required certificates and connected electric loads

Fire detector:
Validity Certificates Requirements
Europe EU Construction One-channel Change-over 24 V DC MTTFd 65a, PLc
Products Direc- contact SIL1
tive / DiBT cer-
tification (Ger-
man civil engi-
neering associa-
tion)
Gas alarm system:

Europe ATEX certifica- At least one- Change-over 24 V DC MTTFd 65a, PLc
tion channel contact SIL1
Type test
Safeguards for coolant circuits

The following details are minimum specifications. They may be higher depending on the project, e.g. for sys-
tems that require monitoring.
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Safety temperature limiter:

Europe e.g. certifica- At least one- Change-over 24 V DC MTTFd > 65a, Minimum
tion acc. to channel contact SIL1 contact load
Water Re- <50mA
sources Act,
VdTüv, prod-
uct standards
MS65032/06E 2021-01 | Control | 47

Safety pressure limiter:
Europe e.g. certifica- At least one- Change-over 24 V DC MTTFd > 65a, Minimum
tion acc. to channel contact SIL1 contact load
Water Re- <50mA
sources Act,
VdTüv, prod-
uct standards
Manual emergency stop

Manual emergency stop:
Europe DIN EN Two-channel Normally- 24 V DC At least PLc/ Minimum
ISO 13850 closed con- SIL1 contact load
tact <50mA
Integration of further safety-related sensors or systems

The following details are minimum specifications. The actual project-specific requirements may be higher.
Further safety-related sensors or systems:
Europe Depending on At least one- Change-over 24 V DC MTTFd > 65a, Minimum
sensor/ channel contact SIL1 contact load
system <50mA
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13 Generator Circuit Breaker
13.1 Selection criteria for generator circuit breaker
The customer’s generator circuit breaker panel must have an option allowing the safe disconnection of the
generator from mains. Consequently, special requirements for the generator circuit breaker have to be met.
When selecting the generator circuit breaker, pay attention to the synchronization capability.
Procedure for safe disconnection of the generator from mains:
• Mains decoupling via undervoltage release element:
Operational shutdown can occur either via an undervoltage release element or via a shunt release ele-
ment. If, however, the power-supply or generator protection mechanism responds or the machine/manual
emergency-stop sequence is triggered, the generator circuit breaker must be opened in a failsafe manner
(no wire breakage) via the undervoltage release element. For safety reasons, therefore, in all cases the
generator circuit breaker must have an undervoltage coil for safe disconnection in the event of a fault.
• Mains decoupling via higher-level switch "open backup switch":
With Series 400/4000, the floating contact is included in the MIP control cabinet.
With Series 500, the floating contact is included in the MMC.
A higher-level switch must be connected to this floating contact. This output is activated if the generator
circuit breaker does not open.
The maximum contact rating of the floating contacts "Close and open generator circuit breaker" and "Open
backup switch" are indicated on the respective circuit diagram.
Additional criteria, such as type of grid, number of poles, rated voltage, rated current, rated short-time with-
stand current, number of switch cycles, etc., as well as local installation conditions or technical connection
conditions, must also be taken into account.
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MS65032/06E 2021-01 | Generator Circuit Breaker | 49

14 Mains Circuit Breaker
14.1 Selection criteria for mains circuit breaker
If the Engine-generator set is intended for mains failure operation, then special requirements for the mains
circuit breaker have to be met.
Requirements for the mains circuit breaker:
• When selecting the mains circuit breaker, pay attention to the synchronization capability according to the
operating mode for the power supply backup operation.
• The setup of the switch for operation is to be realized so that, even in case of power failure, the switch
can be safely opened; one way of achieving this is to use a 24-VDC shunt trip element.
• The setup for the re-engaging of the switch is to be realized so that this function can occur independently
of the state of the engine-generator set. One way of ensuring this is to use a 230-VAC make contact. The
grid power supply system is used for the application of supply/control voltage.
The contact ratings of the “Close and open mains circuit breaker” floating contacts are indicated on the re-
spective circuit diagrams.
Additional criteria, such as type of grid, number of poles, rated voltage, rated current, rated short-time with-
stand current, number of switch cycles, etc., as well as local installation conditions or technical connection
conditions, must also be taken into account.
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15 Cabling
15.1 Electromagnetic compatibility and lines
Electromagnetic compatibility (EMC)
The term electromagnetic compatibility refers to known phenomena such as radio interference, mains pollu-
tion, overvoltage, electromagnetic interference and stray pick-up, etc.
For fault-free operation of the plant, the electromagnetic compatibility must always be included as an inte-
gral part of planning. Further information on appropriate cabling as regards EMC can be found in the installa-
tion manual.
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MS65032/06E 2021-01 | Cabling | 51

15.2 Cable routing
The types of routing of electrical cables is governed in Germany by DIN VDE 0100-520. External influences
on the cabling installation through the routing should be avoided as far as possible. To this end, cables are
routed inside duct systems and cable support systems, pipes are fitted inside walls, clamps are used for fas-
tening and shielded cables are used.
Unprotected installation of cables in the area of double and hollow floors is permissible, provided that the
mechanical loads do not exceed the limit values for the cables. Cables and lines must also be protected at
the ends against the penetration of moisture. The cables and lines types must be selected and installed such
that they can withstand all anticipated external influences.
Influences:
• Water
• Oil
• Influence of other substances ( acid, alkaline solutions..)
• Mechanical influences
• Radiation (UV)
• Heat and cold
• Influence by animals and plants
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15.3 Cable recommendations for the various line groups
The cable list (plant-specific) provided by MTU Onsite Energy lists cable recommendations which must be
checked and adapted to the local conditions, such as type of installation, accumulation, ambient tempera-
ture, resistance, voltage drop, etc., with regard to cable type and wire cross-section.
Line group 1 (LG1)
• Shielded lines for DC and AC voltages
Line group 2 (LG2)
• Unshielded lines for DC and AC voltages
Cable group 3 (LG3)
• Generator wiring <=1000 Volt
Cable group 4 (LG4)
• Geberator wiring >1000 Volt
Line group 1 (LG1) shielded
H05VVC4V5-K (NYSLYCYÖ) Oil-resistant control line, bare stranded copper wire,
fine strands, core insulation and outer sheath on
PVC basis, shielding braid of tinned wires.
Alternative manufacturer's designation: (Ölflex Clas-
sic 140CY)
F-CY-OZ Largely oil-resistant control line, bare stranded cop-
per wire, fine strands, core insulation and outer
sheath made of special PVC.
LiYCY Control line, bare stranded copper wire, finely-
stranded, core insulation, special PVC-based outer
sheath, foil banding, filler strand, shielding braid
made of tinned copper wire.
Alternate manufacturer's designation: Ölflex Classic
115CY or TRONIC-CY
JZ-600-Y-CY / Ölflex Classic 110 CY black Largely oil-resistant control cable, bare copper
strands, fine-stranded, core insulation and outer
sheath made of special PVC, shielding braid made of
tinned wires, UV resistant, suitable for outdoor use.
HELUTHERM 145 MULTI-C Temperature-resistance, halogen-free conductor,
stranded copper wire, core insulation made of polyo-
lefin copolymer, electron beam cross-linked and hal-
ogen-free.
SIHF-C Si Silicone-insulated cable, tinned copper strand, finely-
stranded, free of halogens, increased heat resist-
ance, core insulation, silicone-based outer sheath,
shielding braid made of tinned wire.
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Application: higher ambient temperature
MS65032/06E 2021-01 | Cabling | 53

Line group 1 (LG1) shielded
OZ-BL-CY Special PVC hose-insulated cables with blue sheath,
bare stranded copper wire, finely-stranded, special
PVC insulation for core, outer sheath made of spe-
cial PVC, shielding braid made of tinned copper wire.
Used in potentially explosive atmospheres with igni-
tion type -i-.
Alternate manufacturer's designation: Ölflex EB CY
NiCr / Ni Compensating line NiCr/Ni fine strands, core insula-
tion and outer sheath made of PVC.
Table 9: Line group 1 (LG1)

Line group 2 (LG2) unshielded
NYY Grounding cable 0.6 / 1 kV, power and control ca-
ble, bare copper conductor, single- or multi-wired, in-
sulation for core, PVC outer sheath
H05VV5-F (NYSLYÖ-JZ) Oil-resistant control line, bare stranded copper wire,
fine strands, core insulation and outer sheath made
of PVC.
Alternate manufacturer's designation: Ölflex 140
JZ-600 / Ölflex Classic 110 black Largely oil-resistant control line, bare stranded cop-
per wire, fine strands, core insulation and outer
sheath made of special PVC, UV resistant, suitable
for outdoor use.
HELUTHERM 145 Temperature-stable, non-halogen conductor, strand-
ed copper wire, core insulation made of polyolefin
copolymer, electron beam cross-linked and non-hal-
ogen.
SiHF Silicone-insulated cable, stranded copper wire, fine-
ly-stranded, free of halogens, increased heat resist-
ance, core insulation and silicone-based outer
sheath.
Application: higher ambient temperature
NSGAFöU Special rubber-insulated cable, Cu-braid, tinned,
core insulation made of rubber, intermediate sheath
made of EPR, outer sheath made of polychloroprene.
Used for charging cable for starter battery and gen-
erator measuring voltage!
H01N2-D Oil-resistant harmonized welding cable, stranded
copper wire, finest strands, neoprene outer sheath.
Suitable for the transmission of high currents. Only
suitable for starter cables!
OZ-BL Special PVC hose insulated cable with blue sheath,
Cu-braid, bare, fine strands, core insulation made of
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special PVC, outer sheath made of special PVC.

Used in potentially explosive atmospheres with igni-
tion type -i-.
Alternate manufacturer's designation: Ölflex EB CY
54 | Cabling | MS65032/06E 2021-01

Line group 3 (LG3) power cables
HO7RNF Heavy-duty rubber hose, bare copper conductor,
finely-stranded, rubber insulation for core, polychlor-
oprene outer sheath
RADOX 4 GKW-AX 1800V M Compact, flexible, single-core double-wall power ca-
ble, halogen free, fire retardant, low smoke forma-
tion. Resistance requirements to temperature, abra-
sion, ozone and oil are fulfilled.

Line group 4 (LG4) power cables
XFLEXE-MONO Medium-voltage cable 20 / 12 kV, 10 / 6 kV,
Manufacturer: Leoni Studer AG stranded copper wire bare, compressed in accord-
ance with DIN VDE 0295 / IEC 60228, class 5, inner
conductor screen / dielectric cross-linked / insula-
tion screen.
Extruded in a single processing
step, boundary surface welded
Semiconductor swelling tape: Semiconducting longi-
tudinally watertight tape, copper wire shield with ex-
ternal short-circuit tape
Protective sheath: Elastomer, black with red longitu-
dinal stripes
Table 12: Cable group 4 (LG4)

Important
Generator power cables must always be selected according to intended use and ambient conditions. If
used at the generator, the stranded copper wires must be bare and compressed in accordance with DIN
VDE 0295 / IEC 60228, class 5. Due to the constant movement, rigid cables would be subjected to too
much stress and could be damaged. The same applies to cables made of aluminum. There is a risk of short-
circuiting. To maintain the protection class of the generator terminal box, threaded cable glands are to be
used for the cable entries.
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MS65032/06E 2021-01 | Cabling | 55

15.4 Cross-sectional areas of cables
The cross sections for the generator cables, if included among the delivered items, are designed by MTU. The
recommended data can be obtained from the cable list. As with other lines and cables, the local conditions
are to be considered by the contracting company.
Cross-sections for cables are to be specified by the contracting company in accordance with VDE 0298,
Parts 3 and 4 or IEC 364-5-523. Here the information on the circuit diagrams is to be checked with respect
to the local conditions. Reduction factors with regard to local conditions are to be checked. Additionally, VDE
regulations 0100, 0101, 0271 and 0250 are to be complied with.
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56 | Cabling | MS65032/06E 2021-01

15.5 Generator wiring
The required connecting cable for the generator power cable, its cross-section, etc. must be determined in a
detailed application engineering project. The contracted specialist company must take the current carrying
capacity, voltage drop, other influencing factors, and all possibly required reduction factors into account in
accordance with the relevant standards.
If a busbar system is used for the generator wiring, flexible connecting pieces are to be used at the entry to
the generator terminal box. An appropriate sealing of the busbar inlet is necessary. The design has to ensure
protection against contact and the required type of protection.
Cable routing
Figure 8: Generator power cable (example)

1 Generator 3 Metric cable gland 5 Cable clamp
2 Generator terminal box 4 Cable loop
Sufficient space must be provided for the routing of the generator power cables, with account taken of the
permissible bending radii.
The cables must be fastened in such a way that any mechanical and electrodynamic forces that occur can be
safely controlled. The connecting cables must not exert any force on the connection equipment and apply
TIM-ID: 0000062765 - 004
inadmissible stress.
Sufficient clearance for the cables is to be provided in the area between the engine-generator set and fixed
parts of the building in order to absorb movements of the engine-generator set, thermal expansions and vi-
brations.
Important
For further information and instructions re. wiring, see (→ Assembly Instructions).
MS65032/06E 2021-01 | Cabling | 57

15.6 Protective equipotential bonding and protective conductor
All metallic, electrically conductive components of the product are to be taken account of as regards the
local equipotential bonding.
For selection and installation of the electrical operating equipment, grounding arrangements and protective
conductors, see DIN VDE 0100-540.
The equipotential bonding must comply with DIN VDE 0100–540 and, if necessary, must be adapted to local
legislation and specifications.
Observe the local regulations of the energy supply company and the locally applicable laws and specifica-
tions.
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15.7 Electrical integration (only applicable to Series 4000)
Mains parallel operation (from electrical-/control-related perspective):
The "mains" is defined as a power source if it provides power that is at least ten times as high as the output
of all generators which are connected to it.
To guarantee the function of the engine-generator sets, further interfaces in the customer's system are nec-
essary. In this case, depending on the version of the plant voltage and current transformers are required in
the main current path.
The following variants are available for the electrical integration. For the variants with medium voltage step
up transformer (Figure B / D), an MIP with a second energy measurement module is necessary.
Item Designation
A Low-voltage generator
B Low-voltage generator linked with MV step-up trans-
former
C Medium-voltage generator
D Medium-voltage generator linked with MV step-up
transformer
Table 13: Current paths A - D indicated on diagram

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Figure 9: Electrical integration

1 Mains 4 GCB (generator circuit 7 MTU scope
2 MCB (mains circuit breaker) breaker)
3 Busbar 5 Step-up transformer
6 Customer
MS65032/06E 2021-01 | Cabling | 59

Current transformer requirements
A measuring transformer kit (x / 1A, 1FS5 (at least) 10 VA (or better) and a protection transformer kit (x/
1A, 5P10, 10 VA) are included in the generator terminal box as standard. Project-specific deviations are pos-
sible. For plant systems with a step-up transformer, the customer must provide a measuring transformer kit
(x / 1A, 1FS5 (at least) or better) for placement between the generator circuit breaker and the step-up trans-
former.
It must be ensured that the current transformers do not have a phase shift.
The cross-sectional area of the cable is to be selected so that there is a power of at least 1 VA per phase at
the control cabinet of MTU for the built-in protective devices.
Voltage transformer requirements

For systems > 480V, the customer must provide voltage transformers with x / 100 V class 1 for the busbar
voltage, as well as for the mains measuring voltage in the case of standby systems. For plant systems with a
step-up transformer, the customer must provide a voltage transformer kit (x / 100 V, class 1) for placement
between the generator circuit breaker and the step-up transformer.
It must be ensured that the current transformers do not have a phase shift.
The applicable detailed information can differ on account of special project-specific requirements. The rele-
vant values are indicated in the corresponding circuit diagram documents.
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16 Appendix A
16.1 Index
A Gas system
Application – Customer-provided 21
– As electricity generator 25 – Requirements
– With exhaust gas heat recovery 27 – Customer-provided 22
– With heat recovery 26 Gas train
– Installation recommendations 12
B Generator circuit breaker
Battery – Selection criteria 49
– Installation recommendations 12 Generator wiring 57
Grounding 58
C
I
Cable
– Line groups 53 Installation compartment
Cable cross-sectional areas 56 – Requirements 8
Cable routing 52 Installation recommendations 12
Cables Insulation 44
– Routing 52
L
Catalytic converter 41
Combustion air supply 16 Line groups
Component quality – Recommended cables 53
– Safety components 47 Lines
Connection – Electric 51
– Connection specifications 31 Lube oil system
Connection specifications – Extended
– Connection 31 – Dimensioning 33
– Pipe 31 – Requirements 33
Coolant circuit 24
M
– Design 28
– Electricity generator 25 Mains circuit breaker
– Emergency recooler 30 – Selection criteria for mains circuit breaker 50
– Exhaust gas heat recovery 27 Mains parallel operation
– Heat recovery 26 – Electrical integration 59
D P
Design Pipe
– Coolant circuit 28 – Connection specifications 31
Preface 4
E Premises
Electrical integration – Requirements 7
– Mains parallel operation 59 Product safety
DCL-ID: 0000038771 - 009
Electromagnetic compatibility 51 – Safety of the product 5

Emergency recooler 30 Protective circuits 45
Equipotential bonding 58 Protective conductor 58
Exhaust gas heat exchanger 43 Protective equipotential bonding 58
Exhaust line 38
Exhaust silencer 40
Exhaust system 35
G
Gas quality 23
MS65032/06E 2021-01 | Appendix A | 61

R
Requirements
– Customer-provided gas system 22
– Extended lube oil system 33
– Gas quality 23
– General 6
– Installation compartment 8
– Premises 7
– Switchgear room 11
– Ventilation 19
Room air flow rate
– Room air flow rate 18
Room-air supply
– Ventilation concept 17
S
Safety components
– Component quality 47
Safety functions 45
Safety of the product
– Product safety 5
Selection criteria for mains circuit breaker
– Mains circuit breaker 50
Surface temperature 44
Switchgear room
– Requirements 11
V
Ventilation
– Safety requirements 19
Ventilation system
– Requirements 13
– Tasks 13
DCL-ID: 0000038771 - 009
62 | Index | MS65032/06E 2021-01

Installation Conditions: Gas Engine-Generator Sets With Series 400, Series 500, and Series 4000 Engines

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Installation Conditions: Gas Engine-Generator Sets With Series 400, Series 500, and Series 4000 Engines

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Installation Conditions

Gas engine-generator sets

2 Product Information 10 Exhaust System

4 Room Information 11 Insulation

5.1 Ventilation system 13 13 Generator Circuit Breaker

6 Gas System 14.1 Selection criteria for mains circuit breaker 50

6.1 Customer-provided gas system 21 15 Cabling

MS65032/06E 2021-01 | Table of Contents | 3

4 | Preface | MS65032/06E 2021-01

Integration of machinery / pressure devices / gas appliances

MS65032/06E 2021-01 | Product Information | 5

TIM-ID: 0000062508 - 004

6 | Requirements for Building and Foundation | MS65032/06E 2021-01

MS65032/06E 2021-01 | Room Information | 7

Lifting tools for maintenance work

Fire protection requirements

Explosion protection (OEG)

The Fluids and Lubricants Specifications must be observed.

8 | Room Information | MS65032/06E 2021-01

Ambient conditions (dust, moisture)

Equipotential bonding, protective conductor and grounding

MS65032/06E 2021-01 | Room Information | 9

ZEP - Central grounding point

Manual emergency stop

Installation compartment warnings

Further instruction plates

10 | Room Information | MS65032/06E 2021-01

MS65032/06E 2021-01 | Room Information | 11

12 | Room Information | MS65032/06E 2021-01

MS65032/06E 2021-01 | Ventilation | 13

TIM-ID: 0000062653 - 005

Figure 2: Series 500 ventilation system

14 | Ventilation | MS65032/06E 2021-01

MS65032/06E 2021-01 | Ventilation | 15

Combustion air flow rate

TIM-ID: 0000062660 - 006

16 | Ventilation | MS65032/06E 2021-01

MS65032/06E 2021-01 | Ventilation | 17

Table 3: Nomenclature with descriptions for room air flow rate

18 | Ventilation | MS65032/06E 2021-01

Measures in case of fire

MS65032/06E 2021-01 | Ventilation | 19

TIM-ID: 0000062669 - 004

20 | Ventilation | MS65032/06E 2021-01

MS65032/06E 2021-01 | Gas System | 21

Additional requirements with use of biogas

TIM-ID: 0000062676 - 004

22 | Gas System | MS65032/06E 2021-01

MS65032/06E 2021-01 | Gas System | 23

TIM-ID: 0000062677 - 005

24 | Coolant Circuit, General | MS65032/06E 2021-01

Engine coolant circuit

MS65032/06E 2021-01 | Coolant Circuit, General | 25

Single-stage mixture cooling (Series 400)

Engine coolant circuit

TIM-ID: 0000062682 - 004

26 | Coolant Circuit, General | MS65032/06E 2021-01

MS65032/06E 2021-01 | Coolant Circuit, General | 27

TIM-ID: 0000062686 - 006