Functional Description

Diesel engine-generator sets

with MTU 10/12 V 1600 Gx0 engines
Built in Europe

MS13021/03E
System nomenclature Engine System nomenclature Engine
DS00500D5S 10V1600G70F DP00450D5S 10V1600G10F
DS00550D5S 10V1600G80F DP00500D5S 10V1600G20F
DS00650D5S 12V1600G70F DP00590D5S 12V1600G10F
DS00715D5S 12V1600G80F DP00650D5S 12V1600G20F

Table 1: Applicable engine-generator sets

Printed in Germany
© 2013 Copyright MTU Friedrichshafen GmbH
This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior
written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, mi-
crofilming and storage or processing on electronic systems including data bases and online services.
This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage
during operation.
Subject to alterations and amendments.
 Table of Contents
1 Engine-Generator Set 5.3 Single fuel/water separator 58
5.4 Dual fuel/water separator 61
1.1 Engine-generator set – General information 4 5.5 Fuel cooler 64
1.2 Engine-generator set – Standard scope of
supply 5
6 Air System
1.3 Engine-generator set – Available options 7
1.4 Technical data 9 6.1 Air system 66
6.2 Air filter 68
2 Engine
7 Exhaust System
2.1 MTU Series 1600 Gx0 engine 10
2.2 Engine side and cylinder designations 12 7.1 Exhaust system 70
2.3 Firing order 13 7.2 Exhaust silencer 72
2.4 Sensors and actuators 14
8 Lube Oil System
3 Generator
8.1 Lube oil extraction pump – Mounting
3.1 Generator – General information 16 location 73
3.2 Digital voltage regulator – Overview 19 8.2 Lube oil extraction pump 74
3.3 Digital voltage regulator DVR2000E+ 20
3.4 Digital voltage regulator DVR2000E(C) 24 9 Cooling System

4 Engine-Generator Set Control 9.1 Cooling system 76

9.2 Coolant cooler 78
4.1 Control versions – Overview 30 9.3 Preheater 80
4.2 Smart Connect 31
4.3 Control Version 1 33 10 Electrical System
4.3.1 Control version 1 – Terminal box 33
4.3.2 Terminal box 34 10.1 Starter batteries 84
10.2 Battery charger 86
4.4 Control Versions 2 to 4 35
4.4.1 Control version 2 – Isolated operation (without
10.3 Circuit breaker 88
mains) 35
4.4.2 Control version 3a – With automatic transfer 11 Base and Mounting System
switch 37
4.4.3 Control version 3b – With electrical interlock 11.1 Base frame and mounting 92
circuit breakers 39
4.4.4 Control version 4 – Parallel operation (island) 41 12 Specification Sheets
4.4.5 Control cabinet with DGC-2020 – General
information 43 13 Abbreviations
4.4.6 Control panel DGC-2020 – Display operations 50
13.1 Abbreviations 143
5 Fuel System
DCL-ID: 0000001356 - 004

14 Index
5.1 Fuel system 54
14.1 Index 146
5.2 Fuel prefilter with water separation 56

MS13021/03E 2013-02 | Table of Contents | 3

 1 Engine-Generator Set
1.1 Engine-generator set – General information
The engine-generator set consists mainly of a diesel engine and a generator mounted on a common
base frame. Upon demand, the engine will start and drives the generator to produce electrical power.
Engine-generator sets are available in two application groups: prime power and standby power.

Prime power
Prime power is the need for power, continuously and for long periods of time. It is often used in remote
or developing areas where there is no utility service, where available service is very expensive or unreli-
able, or where customers choose to self-generate their primary power supply.
Prime power Application group 3B
Mode of operation Continuous operation with variable load
Rating definition 10 % overload capacity (ICXN)
Load factor < 75 %
Operating hours unrestricted

Standby power
Standby power systems are a type of system to provide backup resources in a crisis or when regular
systems (e.g. power grid) fail. They find uses in a wide variety of settings from residential homes to hos-
pitals, airports, scientific laboratories and data centers.
Standby power Application group 3D
Mode of operation Standby operation with variable load
Rating definition Fuel stop power (IFN)
Load factor < 85 %
Operating hours max. 500 hours per year

Model designation of engine-generator sets

Key to the engine-generator set model designation
D Type: Diesel engine-generator set
P/S Application:
• P – Prime power (Application group 3B)
• S – Standby power (Application group 3D)
00650 Performance: Rated power in kVA
D Fuel type: Diesel
TIM-ID: 0000038393 - 001

5 Frequency: 50 Hz
S Project type: Standard product

Benefits
• Wide range of standardized engine-generator sets to meet customer requirements with regard to
power, emission and other characteristics
• Possibility to choose from different component designs (e.g. fuel prefilters) and to select options
(e.g. fuel cooler)
• Latest diesel engine technology
• State-of-the-art main components for high efficiency and long service life

4 | Engine-Generator Set | MS13021/03E 2013-02

 1.2 Engine-generator set – Standard scope of supply
The figures show an overview of the standard components on an engine-generator set with a
12 V 1600 Gx0 engine. The figures are also valid for an engine-generator set with a 10 V 1600 Gx0 en-
gine.

Figure 1: Engine-generator set – Generator side view

1 Generator 3 Oil drain
2 Base frame 4 Fuel prefilter
TIM-ID: 0000038403 - 002

MS13021/03E 2013-02 | Engine-Generator Set | 5

 Figure 2: Engine-generator set – Cooler side view
1 Air filter 3 Customer exhaust connec- 5 Cooler
2 Terminal box tion
4 Engine

Standard scope of supply

• MTU Series 10/12 V 1600 Gx0 engine:
– 1,500 RPM (for 50 Hz)
– Air-to-air charge-air cooling
– Electronic engine management system ADEC (ECU8)
• Generator:
– Outlet box inclusive
– Voltage 400 V
– Digital voltage regulator
– IP-20 protection
• Control version 1: Terminal box without control function (interface between engine-generator set and
customer control)
• Smart Connect
• Guards for all rotating parts
• Fuel prefilter with water separation
• Air filter
TIM-ID: 0000038403 - 002

• Oil drain
• Coolant cooler
• Base frame

6 | Engine-Generator Set | MS13021/03E 2013-02

 1.3 Engine-generator set – Available options
The figures show an overview of the optional components on an engine-generator set with a
12 V 1600 Gx0 engine. The figures are also valid for an engine-generator set with a 10 V 1600 Gx0 en-
gine.

Figure 3: Engine-generator set with options– Generator side view

1 Exhaust bellows 3 Exhaust elbow 5 Dual fuel/water separator
2 Fuel cooler 4 Lube oil extraction pump 6 Circuit breaker
TIM-ID: 0000038405 - 002

MS13021/03E 2013-02 | Engine-Generator Set | 7

 Figure 4: Engine-generator set with options – Cooler side view
1 Control cabinet 3 IP-23 drip cover 5 Heat shield
2 Starter battery 4 Preheater

Available options
• Generator:
– Voltages 380 V, 415 V
– Anti-condensation heater
– IP-23 drip cover
– Digital voltage regulator with VAR/PF control feature (available in control version 4 as standard, in
control version 1 as option)
– Kit of three CTs for differential measuring
– Kit of one CT for paralleling (available in control version 4 as standard, in control version 1 as op-
tion)
• Control version 2, 3a, 3b or 4: Control panel DGC-2020 for management and monitoring
• Special fuel prefilter: Single or dual fuel/water separator
• Fuel cooler
• Exhaust bellows
• Exhaust elbow
• Heat shield
• Exhaust silencer
TIM-ID: 0000038405 - 002

• Hand pump for lube oil extraction

• Preheater for engine coolant
• Starter batteries with battery rack and cables
• Battery charger (available in control versions 2, 3a, 3b and 4 as standard, in control version 1 as
option)
• Circuit breaker

8 | Engine-Generator Set | MS13021/03E 2013-02

 1.4 Technical data
The technical data of engine-generator sets are included in specification sheets.
The table shows an overview of the specification sheets.
Engine-generator set Optimization Specification sheet
DP00450D5S fuel optimized (→ Page 99)
exhaust optimized (→ Page 95)
DP00500D5S fuel optimized (→ Page 107)
exhaust optimized (→ Page 103)
DP00590D5S fuel optimized (→ Page 115)
exhaust optimized (→ Page 111)
DP00650D5S fuel optimized (→ Page 123)
exhaust optimized (→ Page 119)
DS00500D5S fuel optimized (→ Page 127)
DS00550D5S fuel optimized (→ Page 131)
DS00650D5S fuel optimized (→ Page 135)
DS00715D5S fuel optimized (→ Page 139)
TIM-ID: 0000038407 - 002

MS13021/03E 2013-02 | Engine-Generator Set | 9

 2 Engine
2.1 MTU Series 1600 Gx0 engine
The figure shows a 12 V 1600 Gx0 engine. It is also valid for an 8 V or 10 V 1600 Gx0 engine.

Figure 5: Engine view on driving end

1 Lifting equipment* 7 Belt drive 13 Oil dipstick
2 Engine governor 8 Cylinder head 14 Oil pan
3 Charge-air intake neck 9 Exhaust manifold 15 Fuel filter
4 Lifting equipment* 10 Crankcase 16 Flywheel
5 Oil filter 11 Engine mounting 17 Flywheel housing
6 Thermostat housing 12 Exhaust turbocharger KS Engine driving end
* Do not use these lifting points to lift the entire engine-generator set.

Series 1600 Gx0 engines with air-to-air charge-air cooling

These engines are compact, powerful, reliable, maintenance-friendly and extremely economical.
Their injection system unites optimum fuel utilization with compliance to the requirements of all rele-
TIM-ID: 0000000733 - 005

vant environmental protection regulations.

10 | Engine | MS13021/03E 2013-02

 Technical data
• Four-stroke diesel engine with four valves per cylinder and direct injection
• 8, 10 or 12 cylinders, 90° V arrangement
• Displacement:
– Per cylinder = 1.75 liters (107 in3)
– Total for 8 V = 14.00 liters (854 in3)
– Total for 10 V = 17.50 liters (1,068 in3)
– Total for 12 V = 21.00 liters (1,281 in3)
• Counterclockwise rotation
• Common rail fuel injection system, electronically controlled fuel injection
• Exhaust turbocharging and air-to-air charge-air cooling
• Engine cooling system with coolant circulation pump and thermostat
• Piston cooling
• Electric starter
• Resilient engine mounting

Engine model designation

Key to the engine model designation 8/10/12 V 1600 Gxyz
8, 10, 12 Number of cylinders
V Cylinder arrangement: V engine
1600 Series
G Application
x Application segment (1, 2, 7, 8)
y Design index
z Frequency code (F = 50 Hz, S = 60 Hz)

Benefits
• Long service life
• High running capacity
• Low fuel consumption
• Engines meet all relevant exhaust emission standards
TIM-ID: 0000000733 - 005

MS13021/03E 2013-02 | Engine | 11

 2.2 Engine side and cylinder designations
Engine sides are always designated as viewed from the driving end (KS).
The cylinders of the left engine side are designated "A" and those of the right side "B" (as per DIN ISO
1204). The cylinders of each bank are numbered consecutively, starting with No. 1 at the driving end.
Other components are numbered in the same way, i.e. starting with No. 1 on driving end.

Figure 6: Engine sides designation

1 Left engine side 3 Right engine side
2 KGS = Free end 4 KS = Driving end

TIM-ID: 0000002185 - 010

12 | Engine | MS13021/03E 2013-02

 2.3 Firing order
Firing order
8V A1–B4–A4–A2–B3–A3–B2–B1
10 V A1–B4–A4–B3–A3–B2–A2–B5–A5–B1
12 V A1–B2–A5–B4–A3–B1–A6–B5–A2–B3–A4–B6

Direction of rotation
Direction of rotation (as viewed on driving end): counter-clockwise, not reversible
TIM-ID: 0000000878 - 003

MS13021/03E 2013-02 | Engine | 13

 2.4 Sensors and actuators

Figure 7: Sensors on engine free end

Item Designation Monitoring of
1 B16 Coolant pressure
2 B6 Coolant temperature
3 B48.2 HP fuel, B side
4 XY39.B1 Injectors, B side
XY39.B2
5 B9 Charge-air temperature
6 B10 Charge-air pressure
7 XY39.A1 Injectors, A side
XY39.A2
8 B48.1 HP fuel, A side
9 B5 Lube oil pressure
TIM-ID: 0000000815 - 003

14 | Engine | MS13021/03E 2013-02

 Figure 8: Sensors on engine driving end
Item Designation Monitoring of
1 M8.1 Fuel pump HDP A (time measurement unit)
2 M8.2 Fuel pump HDP B (time measurement unit)
3 B1 Camshaft TDC
4 B13 Crankshaft speed
TIM-ID: 0000000815 - 003

MS13021/03E 2013-02 | Engine | 15

 3 Generator
3.1 Generator – General information
The electrical generator converts mechanical energy produced by the engine to electrical energy using
electromagnetic induction.
The figure (→ Figure 9) shows a typical generator with its components.

Figure 9: Generator interior view

1 Main rotor assembly 5 Fan 9 Exciter stator
2 Generator lifting point 6 Screen (air outlet) 10 Exciter rectifier assembly
3 Drip cover 7 Main body with main sta- 11 Exciter rotor assembly
4 SAE adapter tor assembly 12 PMG rotor and stator
8 Mounting bracket
Note: Do not use the lifting points (2) to lift the entire engine-generator set.

Benefits
• Exclusive unirotor construction
TIM-ID: 0000035869 - 003

• Superior class H insulation

• Long-life bearing
• Easy access and serviceability
• Extended life applications
• Robust voltage regulation in the presence of harmonic distortion caused by non-linear loads
• Low reactance design to minimize the harmonic voltage distortion caused by non-linear loads
• Front end-mounted outlet box to provide ample space for easy connection

16 | Generator | MS13021/03E 2013-02

 Function
The figure (→ Figure 9) shows the two main parts of a generator: the rotor (1) and the stator (in 7) which
are integrated in the generator main body (7). An outlet box allows good load access from all sides.
570 frames generators are equipped with a 300/250 Hz Permanent Magnet Generator (PMG, 12) exci-
tation support system. This system supplies a minimum short circuit support current of 300 % of rating
for 60 Hz operation (250 % for 50 Hz operation) for 10 seconds.

Controlling
The generator output voltage is controlled by the digital voltage regulator. For further information, refer
to the description of the voltage regulator (→ Page 19).

Cooling
Generators are forced air-cooled. Air enters the lower part of the outlet box at the louvered cover, pass-
es through the stator and rotor coils, and is exhausted as hot air at the adapter ring screened openings
(6). The cast uni-directional aluminum alloy ventilation fan (5), driven by the main rotor (1), provides
even air flow to maximize cooling of the generator.

Outlet box
The outlet box includes various equipment, such as voltage regulator, fuses, CTs. Load connections are
lead through cable grommets into the circuit breaker enclosure. The voltage regulator front panel is op-
erable from outside of the outlet box.
The figure (→ Figure 10) shows the interior of the outlet box which can be equipped in slightly different
variants.
TIM-ID: 0000035869 - 003

Figure 10: Generator outlet box – Interior

1 Outlet box 5 Exciter rectifier assembly 9 Exciter rotor assembly
2 Capacitor 6 Diode standard polarity 10 Exciter stator
3 Bar busses 7 Surge suppressor 11 Fuses
4 Standoff insulator 8 Diode reverse polarity 12 Digital voltage regulator

MS13021/03E 2013-02 | Generator | 17

 The figure (→ Figure 10) shows the generator at exciter end. The outlet box (1) is shown without front
cover to locate the equipment.
The digital voltage regulator panel (12; shown is its rear panel) is accessed from outside the outlet box
through a cut-out. The digital voltage regulator and the capacitor (2) are standard features.
The current transformers (not shown in the figure) are located on the cables that are connected to the
studs on the link board. Fuses (11) are also located inside the outlet box.
Diodes (6, 8) perform the function of an "electrical check valve". They conduct in one direction only and
are used to rectify AC current into DC current. Three forward polarity iodes (6) and three reverse polari-
ty diodes (8) are used. The surge suppressor (7) is polarized. Diodes and surge suppressor are located
on the exciter rectifier assembly (5).
Anti-condensation heaters (not shown in the figure) are optionally available and mounted to the outlet
box of the generator. The heaters are necessary for engine-generator sets operating in a high humidity
region.

Technical data
• Single bearing generator
• 1,500 RPM (for 50 Hz)
• Voltage range: 380 / 400 / 415 V; 3-phase
• Winding type: random wound
• Meets NEMA MG1-22 and MG1-32, BS5000, CSA C22.2, IEC 34-1; AS 1359 and VDE 0530 require-
ments
• CE certified

Identification number
Each generator model is characterized by an identification number. The identification number is located
on the generator nameplate.
Example of the identification number 573RSL4033
573 Frame number
R Winding: Random wound
S Bearing: Single (1 bearing)
L Voltage: Up to 480 V
4033 Model in Series
TIM-ID: 0000035869 - 003

18 | Generator | MS13021/03E 2013-02

 3.2 Digital voltage regulator – Overview
Depending on the control version, different voltage regulators are available:
• Digital voltage regulator (control versions 1, 2, 3a and 3b) (→ Page 20).
• Digital voltage regulator with VAR and PF control features for engine-generator sets in parallel opera-
tion (control version 4; optional for control version 1) (→ Page 24).
TIM-ID: 0000036880 - 002

MS13021/03E 2013-02 | Generator | 19

 3.3 Digital voltage regulator DVR2000E+
The digital voltage regulator is an encapsulated, microprocessor-based control device that regulates the
output voltage of a brushless, AC generator by controlling the current into the generator exciter field. It
is powered by a permanent magnet generator (PMG) and designed for behind-the-panel mounting.
All regulator adjustments are located on the front panel for easy use. The display annunciates regulator
status and system conditions. Push buttons allow adjustment of the various regulator functions. Nor-
mally, the display is covered with a protection plate. The rear panel is accessible from inside the outlet
box.
The figure shows the front panel and the rear panel of the digital voltage regulator.

Figure 11: Digital voltage regulator panels

1 Front panel 5 UP button 9 Serial port
2 Operating interface 6 DOWN button 10 CAN J1939 port
3 SELECT button 7 ENTER button 11 Modbus port
4 Display 8 Rear panel 12 Quick disconnect termi-
nals
TIM-ID: 0000033204 - 005

20 | Generator | MS13021/03E 2013-02

 Features
Operating features
• Voltage regulation to 0.25 %
• Three regulation modes:
– Single phase automatic voltage regulation (AVR1)
– Three-phase automatic voltage regulation (AVR3)
– Field current regulation (FCR)
• 50 or 60 Hz operation
• Preset stability settings
• Adjustable soft start in AVR1 or AVR3 regulation modes
• Underfrequency (volts/hertz) regulation
• Three-phase or single phase generator voltage (RMS) sensing
• Three-phase or single phase generator current (RMS) sensing
• True three-phase power metering
• Field current sensing
• Field voltage monitoring
• Contact inputs for system interface capability
• Contact output for fault indication
• Generator paralleling with reactive droop compensation and reactive differential compensation
• Front-panel human-machine interface (HMI) for status and configuration
• Modbus protocol via RS232 for external communication
• DVR2000E+ Windows ® based software for configuration and monitoring
• Controller Area Network (CAN) interface with CAN 2.0B J1939 protocol for metering and control
• “Power on” LED indicator
• Configurable auxiliary input for metering and control
• CAN capability

Protection features
• Shutdown:
– Field overexcitation shutdown
– Generator overvoltage shutdown
– Generator undervoltage shutdown
– Generator voltage imbalance shutdown
– Loss of generator sensing shutdown
– Field current limiting shutdown
– Regulator overtemperature shutdown
– Instantaneous field overcurrent shutdown
• Alarm:
– Generator underfrequency alarm
– Generator reverse power flow alarm
– Loss of CAN communication alarm

Front panel – Display and operation

The front panel of the digital voltage regulator consists of four push buttons and a 4-digit-display. The
TIM-ID: 0000033204 - 005

display gives out status conditions and failure messages. The push buttons were used to select adjust-
ments during generator installation or service.
The display works in three modes:
• STATUS mode The display shows the non-editable operating state of the digital voltage regulator. The
display flashes while in STATUS mode.
• EDIT mode The display shows a multi-layer menu for reading and editing operating parameters of the
digital voltage regulator. The display is steady-on while in EDIT mode.
• SLEEP mode The display is turned-off after a period of button-press inactivity.
Adjustments are chosen by means of the push buttons.

MS13021/03E 2013-02 | Generator | 21

 Panel push buttons
No. * Button Result
3 SELECT Selects a function for adjustment.
Successive pressing scrolls through the menu.
Serves also as an escape key in EDIT mode.
5 UP Increases the setting level of the function being ad-
justed in steps from the current value to a defined
maximum.
6 DOWN Decreases the setting level of the function being ad-
justed in steps from the current value to a defined
minimum.
7 ENTER Stores the current value of the parameter being ad-
justed and returns the user to the main menu list.
* Numbers correspond to (→ Figure 11).
If regulator power is interrupted before the automatic save feature is commanded, that level of adjust-
ment will be lost.
If no button is pressed for a period of one minute, the regulator saves the settings and exits the adjust-
ment mode.
Notes:
• To change settings, appropriate training by the user is required to avoid malfunctions!
• The engine-generator set must be running before conducting adjustments or settings must be adjust-
ed while engine-generator set is operational.

Rear panel – Communication ports and terminals

Communication ports and terminals on the rear panel consists of four types of connectors:
• Ten quarter-inch, quick-connect terminals for generator connections
• Two 12-pin Deutsch (DTC style) connectors for current transformer (CTs) and system interface con-
nections
• One 3-pin Amp/Tyco Mini Mate-N-Lok receptacle for CAN bus interface
• One 9-pin DB-9 type connector for serial communication between the digital voltage regulator and a
Windows® compatible PC (programming setup)

Operating modes
The digital voltage regulator provides three modes of operation selectable through Windows® or
Palm OS® communication software. Standard features are:
• Automatic voltage regulation mode – Single phase (AVR1)In AVR mode, the digital voltage regulator
regulates the RMS generator output voltage. This is accomplished by sensing generator output volt-
age and adjusting DC output excitation current to maintain voltage at the regulation setpoint.
• Automatic voltage regulation mode – Three-phase (AVR3)In AVR mode, the digital voltage regulator
regulates the RMS generator output voltage. This is accomplished by sensing generator output volt-
age and adjusting DC output excitation current to maintain voltage at the regulation setpoint.
• Manual mode (FCR)In manual mode, also known as field current regulation (FCR) mode, the digital
TIM-ID: 0000033204 - 005

voltage regulator maintains DC excitation current at a set level.

Digital voltage regulator communications software

DVR2000E+ is a Windows® based digital voltage regulator communication software package which is
supplied with the digital voltage regulator.
The software provides a communication link between the digital voltage regulator and the user. The
software enables the user to enter all digital voltage regulator settings and read all system metering
values through an easy to use graphical interface.
For a detailed description of the DVR2000E+ software, please contact your local distributor or dealer.

22 | Generator | MS13021/03E 2013-02

 Registered trademarks
Windows is a registered trademark of Microsoft Corporation.
Palm OS is a registered trademark of Palm, Inc.
TIM-ID: 0000033204 - 005

MS13021/03E 2013-02 | Generator | 23

 3.4 Digital voltage regulator DVR2000E(C)
The digital voltage regulator is a fully encapsulated, static type with a solid state build up circuit. It is
powered by a permanent magnet generator (PMG).
The digital voltage regulator monitors the generator output voltage.
All regulator adjustments and LED indicators are located on the front panel display for easy use and
adjustment. Push buttons allow adjustment of the various regulator functions. Normally, the display is
covered with a protection plate. The rear panel is accessible from inside the outlet box.

Standard features
• Voltage regulation to 0.25 %
• 3-phase RMS sensing
• 50 or 60 Hz operation
• Adjustable under-frequency protection
• Overexcitation / overvoltage protection

Advanced features
• True RMS sensing (single phase or three-phase) Connect the preferred sensing mode. Senses 95 to
600 V ±10 % at 50/60 Hz. Patented circuitry senses true RMS voltage rather than average for superi-
or load regulation.
• Soft-start ramp on initial start-up Controlled increase to rated voltage. Limits overshoot of voltage
during voltage build-up.
• Engine unloading Monitors the rate of frequency change during transient conditions. Provides addi-
tional voltage dip during speed drop to allow engine to recover faster.
• Overvoltage shutdown Provides generator protection during sustained overvoltage. The overvoltage
point is preset at 20 % over normal generator operating voltage, with a preset time out of 0.75 sec-
onds.
• Encapsulated design Maximum protection against moisture or abrasive contamination, which can
lead to early regulator failure. Tested to MIL-STD-705B, method 711.1C; salt fog tested to MIL-
STD-810E.
• Auto/Manual mode Exciter field current can be controlled by the regulator or manually set at a fixed
value.

Operating modes
The digital voltage regulator provides two modes of operation selectable through Windows® or
Palm OS® communication software. Standard features are:
• Automatic voltage regulation mode (AVR)In AVR mode, the digital voltage regulator regulates the
RMS generator output voltage. This is accomplished by sensing generator output voltage and adjust-
ing DC output excitation current to maintain voltage at the regulation setpoint.
• Manual mode (FCR)In manual mode, also known as field current regulation (FCR) mode, the digital
voltage regulator maintains DC excitation current at a set level.
TIM-ID: 0000039262 - 001

24 | Generator | MS13021/03E 2013-02

 Panels

Figure 12: Digital voltage regulator panels

1 Front panel 3 Push button area
2 LED indicator area 4 Rear panel
The figure (→ Figure 12) shows the front panel and the rear panel of the digital voltage regulator.

Front panel – Display operation

The front panel of the digital voltage regulator consists of twelve red LED indicators and three push but-
tons. The LEDs indicate control mode and status conditions and are also used when adjusting settings
at the front panel. The push buttons were used to select adjustments.
The figure (→ Figure 13) shows the front panel in detail.
TIM-ID: 0000039262 - 001

MS13021/03E 2013-02 | Generator | 25

 Figure 13: Digital voltage regulator front panel
1-12 LED indicators 14 UP push button
13 DOWN push button 15 SELECT push button
The front panel offers the following functions:
• Displaying mode status
• Adjusting settings
• Displaying adjustments
The LEDs indicate control mode and status conditions. Mode status LEDs blink approximately twice per
second.

Panel LED indicators (displaying MODE STATUS)

No.* LED Indication
1 Over Excitation Blinks rapidly: The Over Excitation Protection feature
is enabled and the field voltage exceeds the setpoint
(80 V default) for 15 seconds. The digital voltage
regulator will shut down when an overexcitation con-
dition is detected.
Flashes for 5 seconds: The digital voltage regulator
is powered up following an overexcitation condition.
TIM-ID: 0000039262 - 001

2 Over Temperature Blinks rapidly when the internal temperature of the

digital voltage regulator has exceeded its limit and
causes the unit to shut down.
6 Under Frequency Blinks rapidly during an under frequency condition.
8 VAR/PF Active Blinks rapidly when operating in VAR or PF mode.
9 If – Limit Blinks rapidly: The field current exceeds the pro-
grammed overexcitation limit.
* Numbers correspond to (→ Figure 13).

26 | Generator | MS13021/03E 2013-02

 No.* LED Indication
Flashes for 5 seconds: The digital voltage regulator
is powered up following an overexcitation limiting
condition.
10 Manual Mode Blinks rapidly when operating in Manual mode.
11 Loss of Sensing Blinks rapidly: A loss of generator sensing voltage is
detected. The digital voltage regulator will shut
down.
Flashes for 5 seconds: The digital voltage regulator
is powered up following shutdown for loss of genera-
tor sensing condition.
12 Over Voltage Blinks rapidly: The generator output voltage exceeds
the setpoint for 0.75 seconds. The digital voltage
regulator will shut down when a generator overvolt-
age condition is detected.
Flashes for 5 seconds: The digital voltage regulator
is powered up following a generator overvoltage con-
dition.
* Numbers correspond to (→ Figure 13).

Panel push buttons

The adjustments are chosen by means of the three push buttons.
No.* Button Result
13 DOWN Decreases the setting level of the function being ad-
justed in steps from the current value to "MIN".
14 UP Increases the setting level of the function being ad-
justed in steps from the current value to "MAX".
15 SELECT Selects a function for adjustment.
Successive presses of the SELECT push button
scrolls through the list of digital voltage regulator
functions to be adjusted.
* Numbers correspond to (→ Figure 13).
Settings can be adjusted during generator installation or service.
Notes:
• To change settings, appropriate training by the user is required to avoid malfunctions!
• The engine-generator set must be running before conducting adjustments or settings must be adjust-
ed while engine-generator set is operational.
Indication of a setting level is provided by the twelve LEDs. The upper limit of a setting range is repre-
sented by the top LED which is labeled "MAX". The lower limit of a setting range is represented by the
bottom LED which is labeled "MIN".
The LEDs refer to the adjusting settings.
TIM-ID: 0000039262 - 001

Repeatedly pressing the SELECT push button steps through the various adjustments, starting with the
"Course Voltage" adjustment and progressing through to the "Fine Voltage" adjustment. The next press
of the SELECT push button exits the adjustment mode.
When in the adjustment mode, only the adjustment LEDs will be lit. All mode status LEDs will be turned
off.
There are two types of adjustment LEDs:
• The first type is the LED that indicates the function being adjusted. This LED blinks slowly (approxi-
mately once per second).
• The second type is the LED that indicates the level of adjustment. This LED is on steady.

MS13021/03E 2013-02 | Generator | 27

 The level of adjustment is changed by pressing the UP or DOWN push button. When an adjustment level
LED (on steady) overlaps the function LED (slow blinking), the LED will remain in the slow blinking
mode.
If no button is pressed for a period of one minute, the regulator saves the settings and exits the adjust-
ment mode.
If regulator power is interrupted before the automatic save feature is commanded, that level of adjust-
ment will be lost.
When the regulator is not in the adjustment mode and either the UP or DOWN push button is pressed,
the regulator enters the "Fine Voltage" adjustment mode and changes the generator fine voltage set
point by 0.1 V. Successive presses of the UP or DOWN push button shall continue to adjust the fine
voltage setting.
Pressing the SELECT push button causes the regulator to exit the adjustment mode. Mode status LEDs
blink approximately twice per second.

Panel LED indicators (displaying ADJUSTMENTS)

No.* LED Indication
2 Fine Voltage Blinks slowly when the "Fine Voltage" level is select-
ed for adjustment via the front panel push buttons.
3 Gain Blinks slowly when the "Gain" adjustment is selected
for fine tuning of loop gain via the front panel push
buttons.
4 Stability Range Blinks slowly when selecting the desired "Stability
Range" via the front panel push buttons.
5 Droop Blinks slowly when the "Droop" percentage level is
selected for adjustment via the front panel push but-
tons.
6 Under Frequency Blinks slowly when the "Under Frequency" knee
point is selected for adjustment via the front panel
push buttons.
7 VAR/PF Adj. For digital voltage regulators with VAR or PF control
only:
Blinks slowly when the level of the programmed
mode (VAR or PF) is selected for adjustment via the
front panel push buttons.
8 VAR/PF Select For digital voltage regulators with VAR or PF control
only:
Blinks slowly when selecting the programmed mode
(VAR, PF, AVR) via the front panel push buttons.
When in this adjustment mode:
• LED #1 is on solid for none (AVR mode)
• LED #2 is on solid for PF mode
• LED #3 is on solid for VAR mode
TIM-ID: 0000039262 - 001

9 Manual Mode Adj. Blinks slowly when the "Manual Mode" (field current
regulation) set point is selected for adjustment via
the front panel push buttons.
10 Manual Mode On/Off Blinks slowly when selecting or deselecting "Manual
Mode" (field current regulation) as the active operat-
ing mode via the front panel push buttons.
When in this adjustment mode:
• LED #1 is on if Manual mode is off
• LED #2 is on if Manual mode is on
* Numbers correspond to (→ Figure 13).

28 | Generator | MS13021/03E 2013-02

 No.* LED Indication
11 1 - 3 Phase Sensing Blinks slowly when selecting single phase or three-
phase sensing via the front panel push buttons.
When in this adjustment mode:
• LED #1 is on if single phase sensing is selected
• LED #3 is on if three-phase sensing is selected
12 Coarse Voltage Blinks slowly when the "Coarse Voltage" level is se-
lected for adjustment via the front panel push but-
tons.
* Numbers correspond to (→ Figure 13).

Rear panel – Communication port

A communication port is located on the rear panel and consists of a female RS-232 (DB-9) connector.
The communication port serves as an interface for programming setup of the digital voltage regulator.
Programming requires a standard 9-pin serial communication cable connected between the digital volt-
age regulator and an IBM-compatible PC or handheld computer operating with DVR2000E-32 software.

Digital voltage regulator communications software

DVR2000E-32 is a Windows®98/NT based and DVR2000E is a Palm OS®-based digital voltage regulator
communication software package, respectively, which is supplied with the digital voltage regulator.
Both provide a communication link between the digital voltage regulator and the user. The software en-
ables the user to enter all digital voltage regulator settings and read all system metering values through
an easy to use graphical interface.
Proportional Integral Derivative (PID) software within the application enables the user to establish prop-
er PID parameters based on a specified generator and/or exciter time constants. Unit settings can be
saved in a computer file and used later to configure other units with the same settings.
For a detailed description of the DVR2000E/DVR2000E-32 software, contact your local distributor or
dealer.

Registered trademarks
Windows is a registered trademark of Microsoft Corporation.
Palm OS is a registered trademark of Palm, Inc.
TIM-ID: 0000039262 - 001

MS13021/03E 2013-02 | Generator | 29

 4 Engine-Generator Set Control
4.1 Control versions – Overview
Engine-generator set management and monitoring is performed by an engine-generator set control pan-
el.

Control version 1
The engine-generator set is delivered by MTU Onsite Energy for use with a customer-owned control pan-
el:
• Control version 1: Terminal box with Smart Connect module as interface between engine-generator
set and customer`s control system (→ Page 33)
For a description of the terminal box, refer to (→ Page 34).

Control versions 2 to 4
MTU Onsite Energy offers a control cabinet with DGC-2020 microprocessor control panel and various
different control versions to meet customer requirements:
• Control version 2: for single engine-generator set in isolated operation with manual start and stop
(→ Page 35)
• Control version 3a: for single engine-generator set with automatic start and stop signal from the cus-
tomer's automatic transfer switch (ATS) with power failure monitoring (→ Page 37)
• Control version 3b: for single engine-generator set with automatic start and stop, operated with two
electrically interlocked circuit breakers (→ Page 39)
• Control version 4: for up to 15 engine-generator sets in parallel operation (island mode) with remote
start and stop, ethernet connection via load share modules (LSM) (→ Page 41)
Optional control panel accessories:
• Analog expansion module (AEM) for additional analog signals like bearing temperature
• Contact expansion module (CEM) for additional digital signals like switches
For a description of the control cabinet with DGC-2020 and the optional control panel accessories, re-
fer to (→ Page 43).
For a description of the DGC-2020 display operations, refer to (→ Page 50).
TIM-ID: 0000035777 - 002

30 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.2 Smart Connect
The Smart Connect works with the engine governor and is integrated into the engine-generator set con-
trol system. It simplifies the data exchange between the engine-generator set and MTU Service and al-
lows an easy parameter configuration. The display shows occurring errors and status.
The figure shows the Smart Connect module with its integrated 4-digit display.

Figure 14: Smart Connect module

1 Mounting holes 4 DiaSys plugin 7 RS485 interface
2 Display 5 CAN2 bus 8 DIP switches
3 USB interface 6 CAN1 bus 9 Power supply 24 V

Technical data
• DIN-rail mounted housing
• Operating power: 24 V DC
• Power consumption: < 7 W
• USB and RS485 software support (in first step not yet available)

Benefits
TIM-ID: 0000032898 - 002

• Easy parameter configuration for commissioning or service

• Communication between the engine-generator set and other monitoring systems via Standard J1939
• Fast and easy data exchange via USB interface (in next step)

MS13021/03E 2013-02 | Engine-Generator Set Control | 31

 Function
The Smart Connect module simplifies and improves the communication between the engine-generator
set and monitoring systems, operators, service personnal. These functions are provided by the following
components:
• Interface for remote diagnostic dialog via DiaSys
• Interfaces for communication with the engine governor via system cable
• DIP switches for easy parameter setting (speed demand, droop, frequency)
• Display for MTU engine fault codes and Smart Connect specific fault codes and status

TIM-ID: 0000032898 - 002

32 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.3 Control Version 1
4.3.1 Control version 1 – Terminal box
The figure shows the connections between generator, "empty" terminal box and customer for an en-
gine-generator set working with control version 1.

Figure 15: Control version 1

1 Generator voltage sensing C Consumer TB Terminal box
2 Current measuring trans- G Generator
ducer
Note to engine and control panel certification:
When the connection is over the CAN bus (CCB2), communication between the engine and control pan-
el must be certified by MTU.

Characteristics and function

The terminal box for control version 1 has no control function. It is a connection point to allow the cus-
tomer to add a control system. The engine-generator set will then operate from this external control
system with Smart Connect module and Bus card (CCB2) for connection to a non MTU-control panel via
TIM-ID: 0000035039 - 002

CANOPEN/SAE J1939 (optional).

MS13021/03E 2013-02 | Engine-Generator Set Control | 33

 4.3.2 Terminal box
The engine-generator set is delivered by MTU Onsite Energy without a control panel and for use with a
customer control system. The terminal box has no control function and is a connection point to allow
the customer to add a control system.
The figure shows the interior of the terminal box.

Figure 16: Terminal box – Interior

1 Terminal box 3 Terminal blocks
2 Smart Connect module 4 Fuses
For a detailed description of the Smart Connect module (2), refer to (→ Page 31).
TIM-ID: 0000036539 - 002

34 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.4 Control Versions 2 to 4
4.4.1 Control version 2 – Isolated operation (without mains)
The figure shows the connections between generator, control panel and customer for an engine-genera-
tor set working with control version 2.

Figure 17: Control version 2

1 GCB on/off 3 Current measuring trans- CP Control panel with
2 Generator voltage sensing ducer DGC-2020
C Consumer G Generator

Characteristics and function

The control version 2 needs a DGC-2020 control panel delivered by MTU Onsite Energy and is used for
a single engine-generator set which is always connected on a de-energized network. There is no provi-
sion for parallel operation with the mains or other engine-generator sets (not even temporarily for the
un-interruptible switchover to the mains).
The DGC-2020 control panel is mounted in the control cabinet.

Automatic start
TIM-ID: 0000035040 - 003

No manual operation required. The engine-generator set is in "standby". The engine-generator set starts
on request only (remote control), no automatic start, for example, after black out.

With electrically operated (motorized) circuit breaker

If the engine-generator set becomes stable, and no fault conditions are active (failed or a global alarm is
active), the control panel will deliver a 1 second pulse to close the motorized generator circuit breaker
(GCB).

MS13021/03E 2013-02 | Engine-Generator Set Control | 35

 With manually operated circuit breaker
If the engine-generator set becomes stable and no fault conditions are active (failed or a global alarm is
active), the generator circuit breaker (GCB) must be switched on manually.

Automatic stop
No manual operation required. If a remote control started the engine-generator set, the engine-genera-
tor set will automatically stop after the contact is open. The motorized operated GCB switches automat-
ically to the off position. The manually operated GCB must be switched off manually. After stopping, the
engine-generator set is in "standby" again.

TIM-ID: 0000035040 - 003

36 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.4.2 Control version 3a – With automatic transfer switch
The figure shows the connections between generator, control panel, circuit breakers, automatic transfer
switch, customer and main supply for an engine-generator set working with control version 3a.

Figure 18: Control version 3a

1 ATS signal to start/stop 5 MCB on/off CP Control panel with
2 Generator voltage sensing 6 Mains voltage sensing DGC-2020
3 Current measuring trans- A Automatic transfer switch G Generator
ducer C Consumer M Mains supply
4 GCB on/off

Characteristics and function

The control version 3a needs a DGC-2020 control panel delivered by MTU Onsite Energy and is used for
a single engine-generator set operating with ATS (mechanically interlocked automatic transfer switch).
There is no provision for parallel operation with the mains or other engine-generator sets.
The ATS unit includes the supervision of the mains and in case of main failure, an emergency start of
the engine-generator set can be initiated.
The DGC-2020 control panel is mounted in the control cabinet.
TIM-ID: 0000035042 - 001

Automatic start
No manual operation required. The engine-generator set is in "standby". The ATS will start the engine-
generator set automatically if normal voltage does not meet specified requirement or a test run is start-
ed.

Automatic stop
No manual operation required. If an ATS started the engine-generator set, the engine-generator set will
automatically stop after the normal voltage source returns or the test run ends and time delays have
been satisfied. After stopping, the engine-generator set is in "standby" again.

MS13021/03E 2013-02 | Engine-Generator Set Control | 37

 The switchover from the engine-generator set operation back to mains is made with a short interruption
of the supply.

TIM-ID: 0000035042 - 001

38 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.4.3 Control version 3b – With electrical interlock circuit breakers
The figure shows the connections between generator, control panel, customer, circuit breakers and
main supply for an engine-generator set working with control version 3b.

Figure 19: Control version 3b

1 GCB on/off 4 Mains voltage sensing CP Control panel with
2 Generator voltage sensing 5 MCB on/off DGC-2020
3 Current measuring trans- C Consumer G Generator
ducer M Mains supply

Characteristics and function

The control version 3b needs a DGC-2020 control panel delivered by MTU Onsite Energy and is used for
a single engine-generator set operating with two electrically interlocked circuit breakers. The circuit
breakers are controlled by the engine-generator set control panel. There is no provision for parallel op-
eration with the mains or other engine-generator sets.
The control panel monitors the mains supply and in case of main failure, an emergency start of the en-
gine-generator set can be initiated. In addition, the engine-generator set can be started by a remote
signal.
The DGC-2020 control panel is mounted in the control cabinet.
TIM-ID: 0000035778 - 001

Automatic start
The engine-generator set is in "standby". In case of mains failure and after the mains fail transfer delay
has expired, then the MCB (mains circuit breaker) opens and the generator starts. Wait for the genera-
tor stable timer, and then the GCB (generator circuit breaker) closes. The engine-generator set then
provides load to the consumer.

MS13021/03E 2013-02 | Engine-Generator Set Control | 39

 Automatic stop
When the bus is re-applied or the bus condition parameters are re-adjusted to indicate a stable bus in-
put and after the mains fail return delay has expired, then the unit will open the GCB, close the MCB,
cool down and stop.
The switchover from engine-generator set operation back to mains is made with a short interruption of
the supply.

TIM-ID: 0000035778 - 001

40 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.4.4 Control version 4 – Parallel operation (island)
The figure shows the connections between the engine-generator sets working with control version 4.

Figure 20: Control version 4

1 GCB on/off 4 Load share line (Ethernet G Generator
2 Generator voltage sensing connection) L Load share module
3 Current measuring trans- C Consumer
ducer CP Control panel with
DGC-2020

Characteristics and function

The control version 4 needs a DGC-2020 control panel and load sharing modules (LSM) delivered by
MTU Onsite Energy. Control version 4 is used for up to 15 engine-generator sets in parallel working in
an island network. There is no provision for parallel operation with the mains.
After a remote start signal, the engine-generator set starts, synchronizes and switches “On” automati-
cally. This operation mode has no main failure monitoring. It is assumed that the mains switch is moni-
tored and controlled by a separate control device.
The DGC-2020 control panel and the load sharing module (LSM) are mounted in the control cabinet.
TIM-ID: 0000035041 - 001

Automatic start
No manual operation is required. All of the engine-generator sets are in "standby". The engine-generator
sets start on request only (remote control), there is no automatic start, for example, after black out.
If a number of engine-generator sets are stable and ready to close their generator breaker to a dead
bus, each must issue a dead bus close request to the system manager, which issues a dead bus close
grant to one machine in order to close the bus. The first machine to issue a request to the system man-
ager is the one allowed to close.

MS13021/03E 2013-02 | Engine-Generator Set Control | 41

 If the system manager receives several dead bus close requests at the same time, it issues the grant to
the machine with the lowest numbered sequencing ID. No individual unit can close to the dead bus un-
less it has received a dead bus close grant from the system manager. Once the unit that has received
the dead bus close grant has closed to the dead bus, the remaining machines must synchronize and
then close to the bus.
If the system manager machine goes out of service, the system manager role moves to the machine
among those remaining with the lowest numbered generator sequencing ID. It is required that all ma-
chines in a multiple machine system have different sequencing IDs.
If only one machine of a multiple machine system is in service, that can close to a dead bus at will since
it will be aware no other machines of the system are in service.

Automatic stop
No manual operation required. If a remote control started all of the engine-generator sets, the engine-
generator sets will automatically stop in different ways.
If several machines are in parallel driving a load and one of the machines receives the automatic stop,
that unit will gradually unload, ramping down its power output to a low level. When the power level is
below the level specified by the "Breaker open set point" setting, the machine will open its breaker and
shut down.
If a machine receives the automatic stop and it is the only machine of the system that is running, and it
receives the automatic stop, it will open its breaker and shut down.
If several machines are operating in parallel and all machines receive the automatic stop, they will all
open their breakers and shut down.

TIM-ID: 0000035041 - 001

42 | Engine-Generator Set Control | MS13021/03E 2013-02

 4.4.5 Control cabinet with DGC-2020 – General information
The control panel is the local control console and emergency control station for the engine-generator
set. Its control and display elements provide status and alarm information and allow quick start/stop/
emergency stop operations. The screen display is controlled by a key pad beneath the display panel.
Command input for generator-set operation and alarm handling is provided by additional control keys
on the display panel.
The control panel communication software allows units to be easily customized for each application.
The figure (→ Figure 21) shows the mounting location of the control cabinet.

Figure 21: Control cabinet with DGC-2020 – Mounting location

1 Control cabinet 2 Control panel display 3 Emergency stop button
TIM-ID: 0000035870 - 002

MS13021/03E 2013-02 | Engine-Generator Set Control | 43

 Figure 22: Control cabinet with DGC-2020 – Exterior
1 Control cabinet 3 Audible alarm 5 Latch
2 DGC-2020 display 4 Emergency stop button
The control cabinet (1) allows the access to the engine-generator set by the panel/display of
DGC-2020 (2). The emergency stop button (4) ensures easy access in the case of emergency. The audi-
ble alarm (3) emits an alarm tone in case of troubles or emergency. The control cabinet is locked
against unauthorized access by latches (5).
The interior of the control cabinet is shown in (→ Figure 23).

TIM-ID: 0000035870 - 002

44 | Engine-Generator Set Control | MS13021/03E 2013-02

 Figure 23: Control cabinet with DGC-2020 – Interior
1 Control cabinet 4 Fuses 7 Load share module (for
2 Smart Connect module 5 Analog expansion module control version 4)
3 Terminal blocks (optional) 8 Battery charger
6 Contact expansion module
(optional)
For a detailed description of the Smart Connect module (2), refer to (→ Page 31).
For a detailed description of the battery charger (9), refer to (→ Page 86).
For a brief description of the optional analog expansion module (5), contact expansion module (6) and
load share module (7), see below.

Digital Genset Controller DGC-2020

The DGC-2020 installed in MTU Onsite Energy engine-generator sets is a highly advanced, integrated
engine-generator set control system. The DGC-2020 is perfectly focused, combining rugged construc-
tion and microprocessor technology to offer a product that will hold up to almost any environment and
flexible enough to meet your application's needs. This device provides engine-generator set control,
metering, protection and programmable logic in a simple, easy-to-use, reliable, and cost effective pack-
age.
TIM-ID: 0000035870 - 002

MS13021/03E 2013-02 | Engine-Generator Set Control | 45

 Features
• Engine metering and protection
• Emergency stop
• Current sensing (5 A CT inputs)
• System protection and supervision:
– Under-/Overvoltage
– Under-/Overfrequency
– Overcurrent
– Phase imbalance
– Loss of mains protection (available with control versions 2 and 3a/b)
– Loss of excitation
– Reverse power
– Overload relay
– Bus under-/overvoltage
– Bus under-/overfrequency
• 15 contact outputs:
– Factory utilized: three 30 ADC and two 2 ADC rated contacts
– User-defined: ten 2 ADC rated contacts
• 16 inputs
• Battery backup for Real Time Clock (RTC)
• LCD heater
• Modbus communications (via RS-485 communications port and Modbus RTU protocol)
• SAE J1939 CAN bus engine ECU communications
• Extremely rugged, fully encapsulated design
• Wide ambient temperature range
• UL/CSA approvals: cURus approved to UL 508 R and CSA C22.2 No. 14
• HALT (Highly Accelerated Life Tests) tested
• IP54 front panel rating with integrated gasket
• NFPA 110 level compatible
• Windows ® based control panel communication software
– Programming and setup software – intuitive and powerful
– Programmable logic
– USB communications
• Multilingual capability (English, Spanish, Chinese)
• Event recording

Accessories depending on the control version

• Analog expansion module AEM, optional for winding and bearing RTD (generator accessories)
• Contact expansion module CEM, optional for potential-free contacts
• Load share module LSM, standard with control version 4 for engine-generator set in parallel opera-
tion
• Automatic synchronizer (DGC-2020 advanced level), standard with control version 4 for engine-gen-
erator set in parallel operation

Analog expansion module

The analog expansion module is a remote auxiliary device that provides additional DGC-2020 analog
TIM-ID: 0000035870 - 002

inputs and outputs. Its features include:

• Eight RTD inputs (six for winding, one for bearing); for monitoring generator temperature (protect
against high temperature conditions)
• Communications to the DGC-2020 via CAN bus

Contact expansion module

The contact expansion module is programmed to display operating conditions (potential-free contacts):

46 | Engine-Generator Set Control | MS13021/03E 2013-02

 • Global (Pre-alarm)
• Global (Alarm)
• Not in AUTO
• Low fuel level (Pre-alarm)
• Fuel leak
• Low coolant level
• Low oil pressure (Pre-alarm)
• Low oil pressure (Alarm)
• High engine temperature (Pre-alarm)
• High engine temperature (Alarm)
• Low engine temperature (Pre-alarm)
• Generator breaker closed
• Generator breaker tripped
• Engine running
• Overcrank
• Overspeed (Alarm)
• Battery overvoltage (Pre-alarm)
• Low battery voltage (Pre-alarm)
• Emergency system supplying load
The communications to the DGC-2020 takes place via CAN bus.

Load share module

The load share module is an easy-to-connect and use optional module for the DGC-2020 to allow the
DGC-2020 to control the kW load sharing of a paralleled engine-generator set. The load share module
communicates to the DGC-2020 via CAN bus communications.
The load share module has three analog outputs:
• one is connected to the voltage regulator
• one is connected to the speed governor
• one is connected to the load sharing lines
This module also adds demand start/stop control and generator sequencing to the feature packed
DGC-2020.
The generator sequencing can be selected by priority number, generator size, service hours remaining,
and balanced service hours. This sequencing function is even smart enough to determine if all the con-
nected control panels are in the same mode.

Automatic synchronizer
When the DGC-2020 is configured with this option, it can be selected between two types of automatic
synchronizers: phase lock or anticipatory style.
In both methods, the DGC-2020 adjusts generator frequency and voltage to match that of the bus
(mains) via analog outputs, then connects the generator to the bus by closing the connecting breaker.
TIM-ID: 0000035870 - 002

MS13021/03E 2013-02 | Engine-Generator Set Control | 47

 Functions
Engine-generator set protection
• Generator protection
– Undervoltage
– Overvoltage
– Underfrequency
– Overfrequency
– Reverse power
– Loss of excitation
– Overcurrent
– Phase imbalance
– Rate of change of frequency
– Vector shift
• Engine-generator set alarms, protected by DGC-2020
– Low oil pressure
– Engine sender unit failure
– Overcrank
– Overspeed
– Low coolant level
– High coolant temperature
– Low fuel level
– Fuel leak/fuel sender failure
– Emergency stop
• Engine-generator set pre-alarms, protected by DGC-2020
– Low oil pressure
– High coolant temperature
– Low coolant temperature
– Battery overvoltage
– Battery charger failure
– Weak battery
– Engine sender unit failure
– Engine kW overload low
– Maintenance interval timer
– Fuel leak detect
– Low fuel level

Engine-generator set metering

• Generator parameters include voltage, current, frequency, real power (watts), apparent power (VA),
and power factor (PF).
• Engine parameters include oil pressure, coolant temperature, RPM, battery voltage, fuel level, engine
runtime, and various CAN bus supported parameters.

Engine control
• Cranking control
• Engine cool-down: smart cool-down function saves fuel and engine life
TIM-ID: 0000035870 - 002

• Successful start counter: counts and records successful engine starts

• Timers:
– Engine cool-down timer
– Pre-alarm time delays for weak/low battery voltage
– Alarm time delay for overspeed
– Alarm time delay for sender failure
– Continuous or cycle cranking time delay
– Arming time delays after crank disconnect for: low oil pressure, high coolant temperature

48 | Engine-Generator Set Control | MS13021/03E 2013-02

 Event recording
The DGC-2020 has an event recorder that provides a record of alarms, pre-alarms, engine starts, engine
runtime loaded, engine runtime unloaded, last run date, and many other events that are all date and
time stamped to help the user determine the cause and effect of issues related to the engine-generator
set. It contains 30 event records each retaining up to 99 occurrences in memory. Time, date and engine
hour detail is available for the most current 30 occurrences within each event record.

Technical data
Operating power Values
Nominal 12 or 24 VDC
Range 6 to 32 VDC
Power consumption in 5 W with all relays non-energized
sleep mode
Power consumption in 14.2 W in RUN mode, with LCD heater on and 6 relays energized
typical operation
mode
Battery ride through Withstands cranking ride-through down to 0 V for 50 ms (typical)

Environmental con- Values

dition
Temperature Operating: -40 to 70 °C (-40 to 158 °F)
Storage: -40 to 85 °C (-40 to 185 °F)
Humidity IEC 68-2-38
Salt Fog ASTM B 17-73, IEC 68-2-11 (tested while operational)
Ingress Protection IEC IP54 for front panel
Shock 15 G in 3 perpendicular planes
Vibration 5 to 29 to 5 Hz: 1.5 G peak for 5 min.
29 to 52 to 29 Hz: 0.036" double amplitude for 2.5 min.
52 to 500 to 52 Hz: 5 G peak for 7.5 min.
Swept over the following ranges for 12 sweeps in each of three mutually perpen-
dicular planes with each 15-minute sweep

Display operations
The front panel display is used to make settings changes and to display metering values.
The wide temperature-range LCD with backlighting can be viewed under a wide range of ambient light
and temperature conditions.
For further information to the main display operations, refer to (→ Page 50).

Control panel communication software

For a detailed description of the communication software, contact your local distributor or dealer.
TIM-ID: 0000035870 - 002

Registered trademark
Windows is a registered trademark of Microsoft Corporation.

MS13021/03E 2013-02 | Engine-Generator Set Control | 49

 4.4.6 Control panel DGC-2020 – Display operations
Front panel display
The front panel display is used to make settings changes and display metering values.
The wide temperature-range LCD with backlighting can be viewed under a wide range of ambient light
and temperature conditions. The figure shows the display of the DGC-2020 in detail.

Figure 24: Control panel with DGC-2020 – Controls and indicators

1 ALARM SILENCE push but- 5 RUN push button and 9 "Not in AUTO" indicator
ton mode indicator 10 Alarm indicator
2 LAMP TEST push button 6 RESET push button 11 Supplying load indicator
3 AUTO push button and 7 Arrow push buttons 12 Liquid Crystal Display
mode indicator 8 EDIT push button (LCD)
4 OFF push button and
mode indicator

Panel LED indicators

No.* LED Indication
3 Auto Green – Indicates the unit is in the AUTO mode of
TIM-ID: 0000000147 - 009

operation.
4 Off Red – Indicates the DGC is in the OFF mode.
5 Run Green – Indicates the DGC is in the RUN mode.
9 Not in Auto Red – Indicates unit is not in the AUTO mode.
10 Alarm Red – Indicates an alarm situation by continuous illu-
mination.
* Numbers correspond to (→ Figure 24).

50 | Engine-Generator Set Control | MS13021/03E 2013-02

 No.* LED Indication
Indicates a pre-alarm by flashing.
11 Supplying Load Green – Indicates the system is supplying current to
a connected load.
* Numbers correspond to (→ Figure 24).

Panel push buttons

No.* Button Result
1 ALARM SILENCE Stops the currently occurring audible alarm.
2 LAMP TEST Tests the DGC-2020 indicators by exercising all LCD
pixels and lighting all LEDs.
3 AUTO Places the DGC-2020 in AUTO mode.
The green LED lights when AUTO mode is active.
4 OFF Places the DGC-2020 in OFF mode.
The red LED lights when OFF mode is active.
5 RUN Places the DGC-2020 in RUN mode.
The green LED lights when RUN mode is active.
6 RESET Cancels an editing session and discards any settings
changed.
When pressed, this button also resets the Breaker
Management Pre-alarms.
7 (arrows) Navigates through the front panel display menus and
modifies settings.
The left- and right-arrow buttons are used to navi-
gate through the menu levels.
• The right-arrow button is pressed to move down-
ward through the menu levels.
• The left-arrow button is pressed to move upward.
Within a level, the up-arrow and down-arrow buttons
are used to move among items within the menu lev-
el.
• Pressing the down-arrow button moves to items
lower in the list.
• Pressing the up-arrow button moves to items
higher in the list.
During an editing session, the up- and down-arrow
buttons are used to raise and lower the value of the
selected setting.
8 EDIT Starts an editing session and enables changes to
DGC-2020 settings.
At the conclusion of an editing session, the Edit push
button is pressed again to save the setting chances.
* Numbers correspond to (→ Figure 24).
TIM-ID: 0000000147 - 009

Login/logout and permissions

Note: To change settings, an appropriate training to the user is required to avoid malfunctions!

MS13021/03E 2013-02 | Engine-Generator Set Control | 51

 1. To login, navigate to the SETTINGS → ENTER PASSWORD screen and press the EDIT push button.
2. Enter the password.
• Use the up/down-arrow push buttons to scroll through the characters.
• Use the left/right-arrow push buttons to enter more characters.
3. Press the EDIT push button to login. The LOGOUT selection now appears in the list of SETTINGS.
4. ... select your further operations ...
5. To logout, navigate to SETTINGS → LOGOUT and press the EDIT push button. The LOGOUT selection
is removed from the list of SETTINGS.

Summary screen
Note: To change settings, an appropriate training to the user is required to avoid malfunctions!
The summary screen can be set to standard or scrolling.
Set the summary screen
1. Click right arrow to select a standard or scrolling summary.
2. Navigate to the SETTINGS → GENERAL SETTINGS → FRONT PANEL HMI screen.
3. Click EDIT. Enter user ID and password as needed.
4. Edit the SUMMARY VIEW. The SCROLL DELAY setting is also found on the screen.
When set to standard, the following values are displayed:
VOLT* AMP* PH* Hz OIL FUEL TEMP BATT

* Information for each phase is obtained by pressing the up-/down-arrow buttons on the front pan-
el.
When the summary screen is set to scrolling, you can select/configure the metering values that are
displayed. Up to 20 values can be displayed and these values will scroll at a delay time specified by the
user.
Select the scrolling values
1. Navigate to the SETTINGS → GENERAL SETTINGS → FRONT PANEL HMI screen.
2. Edit the CONFIGURABLE METERING.
The following values may be selected by the user to be placed in the scrolling summary:
NONE* BATT V GEN VAB GEN VAN KW A KVA A GEN Hz GEN IA
BLANK** RPM GEN VBC GEN VBN KW B KVA B GEN PF GEN IB
OIL P RPM SRC GEN VCA GEN VCN KW C KVA C BUS Hz GEN IC
TEMP FUEL RUN HRS KWH KW TOT KVA TOT BUS V

* Removes a line from the scrolling list.

** Shows nothing on this line.

Remote access
If communications access is active through the modem or USB, the front panel will display "REMOTE
COMMS, FRONT PANEL IS READ ONLY" and the summary screen. This informs that the front panel can
TIM-ID: 0000000147 - 009

only be used for viewing metering data and settings information. Remote access must be ended before
modifying settings through the front panel.

Sleep mode
The sleep mode serves as a power saving feature. If the DGC-2020 is in OFF mode or AUTO mode not
running and a key is not pressed for more than 15 minutes, the front panel LCD backlight and LCD
heater are turned off. The DGC-2020 resumes normal display operation when any front panel button is
pressed or the engine-generator set is started remotely via the ATS input.
The DGC-2020 will not go to sleep while in an alarm state. If needed, the sleep mode can be perma-
nently disabled via the control panel communication software or the front panel menu.

52 | Engine-Generator Set Control | MS13021/03E 2013-02

 As a default, the sleep mode is disabled at the factory, however, it can be re-initiated.

Control panel communication software

For a detailed description of the communication software, please contact your local distributor or deal-
er.
TIM-ID: 0000000147 - 009

MS13021/03E 2013-02 | Engine-Generator Set Control | 53

 5 Fuel System
5.1 Fuel system
The fuel system provides the engine with fuel. The fuel source is a fuel tank which can be located below
or beside the engine-generator set or outside the engine-generator set room. The fuel tank is connected
to the fuel delivery pump via fuel hoses.
The fuel system is controlled by the electronic engine management system and guarantees an optimal
fuel supply for each application.
The figure shows the fuel system of a 12 V 1600 Gx0 engine. The figure is also valid for an 8 or
10 V 1600 Gx0 engine.

Figure 25: Fuel system

1 Fuel return line 5 Fuel return from cylinder 9 HP pump
2 HP fuel line head a Fuel supply
3 HP accumulator (rail) 6 Fuel filter b Fuel return
4 Injector 7 Fuel return to fuel tank KS Engine driving end
8 Hand pump
TIM-ID: 0000036337 - 001

Technical data
The fuel system consists of low pressure and high pressure fuel systems, the fuel return system and a
fuel control system.
Low pressure (LP) fuel system:
• Fuel delivery pumps, integrated in the HP fuel pumps
• Fuel hand pump
• Fuel filter
• Fuel prefilter
• Fuel cooler (optional)

54 | Fuel System | MS13021/03E 2013-02

 High pressure (HP) fuel system:
• HP fuel pumps
• Common pressure accumulators (common rails)
• Single-wall HP fuel lines
• Injectors with individual accumulator and flow restriction valve
Fuel return system:
• Return lines from the cylinder heads
• Return lines from the HP fuel pumps
• Return lines from the common rails
Fuel control system:
• Control by electronic engine management system
• Electronically controllable (variable) injection start and injection end

Benefits
• Low exhaust emissions and low fuel consumption over the entire power range
• Excellent acceleration and load acceptance performance
• Injection time and amount of injected fuel electronically controlled
• Exemplary smooth running and high speed stability
• No power loss at high fuel temperatures

Function
The low pressure fuel delivery pumps (integrated in the HP pumps) draw fuel from the fuel tank via the
fuel prefilter and the hand pump (8) to the fuel filter (6) and, finally, to the HP pumps (9). The HP pumps
increase the fuel pressure up to 1600 bar and deliver fuel via the HP fuel fill lines (2) to the common
rails (3). Separate HP fuel lines supply the fuel to the injectors (4).
Fuel injected by the injectors is distributed evenly in the combustion chamber. The start of injection
and injection quantity is electronically controlled by the engine governor. Surplus fuel is led from the
common rails via the fuel return line (1) and from the cylinder heads via the fuel return lines (5) back to
the fuel tank (7).
To avoid hot fuel flowing back into the fuel tank, an optional fuel cooler can be mounted in the return
line to the fuel tank.
The hand pump supports manually filling and venting of the fuel system.
The following alternative fuel prefilters can be selected:
• Fuel prefilter with water separator (standard)
• Single fuel/water separator (option)
• Dual fuel/water separator (option)

Available option
• Fuel cooler
TIM-ID: 0000036337 - 001

MS13021/03E 2013-02 | Fuel System | 55

 5.2 Fuel prefilter with water separation
The fuel prefilter provides additional fuel filtration before going through the integral on-engine filtration.
It is installed in the intake line of the fuel delivery pump. It removes water and any solid contaminants
found in the fuel, thus protecting the delivery pump.
The figure shows the fuel prefilter with water separation.

Figure 26: Fuel prefilter

1 Fuel outlet connection 3 Fuel inlet connection 5 Drain bowl with drain valve
2 Adapter 4 Filter bowl with filter ele- 6 Mounting rack
ment

Technical data
• Filter element material: mesh of high-tin bronze
• Particle retention: 10 μm
• Capacity of 0.5 liters
• Removes solid contaminants from the fuel
• Separates water from the fuel

Benefits
TIM-ID: 0000035863 - 001

• Most compact design

• High efficiency
• Low flow restriction
• Long life filter element
• Easy installation and simple maintenance

Function
The fuel is supplied via the inlet connection (3) to the filter bowl (4), where it flows through the filter
element from outside to inside and is filtered. The cleaned fuel then passes through the outlet connec-
tion (1).
56 | Fuel System | MS13021/03E 2013-02
 Any contaminants suspended in the fuel are retained on the outside of the filter element and collect at
the bottom of the drain bowl (5). There, also the water separated from the fuel is collected. All can be
drained via the drain valve.
The filter bowl (4) are screwed on an adapter (2) which is fit to the engine-generator set by means of a
mounting rack (6).
TIM-ID: 0000035863 - 001

MS13021/03E 2013-02 | Fuel System | 57

 5.3 Single fuel/water separator
The single fuel/water separator is installed in the intake line of the fuel delivery pump. It removes solid
and liquid contaminants found in the fuel.
The figure (→ Figure 27) shows the mounting location of the single fuel/water separator.

Figure 27: Single fuel/water separator – Mounting location

1 Single fuel/water separa- 2 Fuel return (from engine) 3 Fuel outlet connection (to
tor engine)
The figure (→ Figure 28) shows the single fuel/water separator.

TIM-ID: 0000035957 - 002

58 | Fuel System | MS13021/03E 2013-02

 Figure 28: Single fuel/water separator
1 Fuel outlet connection (to 4 Mounting clamp 7 Drain valve
engine) 5 Fuel inlet connection (to
2 Tommy screw filter)
3 Filter housing with filter el- 6 Bowl with centrifugal filter
ement

Technical data
• Water separator and fuel filter for standard diesel fuel
• 3-stage filtration (multi-stage centrifugal system)

Benefits
• Most compact design
• High efficiency
• Low flow restriction
• Long life filter element
• Easy installation and simple maintenance

Function
TIM-ID: 0000035957 - 002

The single fuel/water separator consists of one filter housing (3). The fuel passes through an inlet con-
nection (5), flows through the filter housing, centrifugal filter (inside 6) and the bowl (6) to the filter ele-
ment (inside 3). There, the fuel flows from outside to inside and is filtered in three stages.

MS13021/03E 2013-02 | Fuel System | 59

 Filter stages Meaning
1st stage Separation: Using the fuel flow, the turbine separates large solids and free water
through enhanced centrifugal force.
2nd stage Coalescing: Smaller water droplets and solids coalesce on the conical baffle and
fall to the collection bowl.
3rd stage Filtration: Engines will benefit from near 100 % water separation and fuel filtration
with water repelling media. The replaceable filter elements are available in 10 mi-
cron ratings.

The cleaned fuel then passes through the outlet connection (1).
By venting the filter and draining the contaminants and water from the bowl (6) at the drain valve (7),
the filter element is flushed in the opposite flow direction and cleaned again.

TIM-ID: 0000035957 - 002

60 | Fuel System | MS13021/03E 2013-02

 5.4 Dual fuel/water separator
The dual fuel/water separator is installed in the intake line of the fuel delivery pump. It removes solid
and liquid contaminants found in the fuel.
The figure (→ Figure 29) shows the mounting location of the dual fuel/water separator.

Figure 29: Dual fuel/water separator – Mounting location

1 Dual fuel/water separator 2 Fuel return (from engine) 3 Fuel outlet connection (to
engine)
The figure (→ Figure 30) shows a dual fuel/water separator.
TIM-ID: 0000035955 - 002

MS13021/03E 2013-02 | Fuel System | 61

 Figure 30: Dual fuel/water separator
1 Fuel outlet connection (to 5 Diverter lever 9 Mounting rack
engine) 6 Fuel inlet connection (to 10 Pressure gauge
2 Tommy screw filter)
3 Filter housing with filter el- 7 Bowl with centrifugal filter
ement 8 Drain valve
4 Mounting clamp

Technical data
• Filter, switchable
• Water separator and fuel filter for standard diesel fuel
• 3-stage filtration (multi-stage centrifugal system)

Benefits
• Most compact design
• High efficiency
• Low flow restriction
• Long life filter element
• Easy installation and simple maintenance
• Replacement of filter while engine is running
TIM-ID: 0000035955 - 002

Function
The dual fuel/water separator (→ Figure 30) is a filter consisting of two single filters operating in paral-
lel. The diverter lever (5) allows to isolate one fuel filter at a time for servicing the bowl (7) or the filter
element (inside 3) without stopping the engine.
The fuel passes through an inlet connection (6), flows through the filter housing (3), centrifugal filter (in-
side 7) and the bowl (7) to the filter element (inside 3). There, the fuel flows from outside to inside and
is filtered in three stages.

62 | Fuel System | MS13021/03E 2013-02

 Filter stages Meaning
1st stage Separation: Using the fuel flow, the turbine separates large solids and free water
through enhanced centrifugal force.
2nd stage Coalescing: Smaller water droplets and solids coalesce on the conical baffle and
fall to the collection bowl.
3rd stage Filtration: Engines will benefit from near 100 % water separation and fuel filtration
with water repelling media. The replaceable filter elements are available in 10 mi-
cron ratings.

The cleaned fuel then passes through the outlet connection (1).
By venting the inoperative filter and draining the contaminants and water from the bowl (7) at the drain
valve (8), the filter element is flushed in the opposite flow direction and cleaned again.
A pressure gauge (10), located at the fuel outlet, monitors the pressure differential between new-status
pressure and deviating pressure during operation.
TIM-ID: 0000035955 - 002

MS13021/03E 2013-02 | Fuel System | 63

 5.5 Fuel cooler
The very high injection pressure in the engine leads to an increase of the fuel temperature when the
surplus fuel is sent back to the fuel tank via the return line. This can result in extremely hot fuel that
may exceed the material limitations of the fuel tank and the injection equipment.
A fuel cooler reduces the fuel temperature in the fuel return line and in the day tank.
The figure (→ Figure 31) shows the mounting location of the fuel cooler.

Figure 31: Fuel cooler – Mounting location

1 Fuel cooler
The figure (→ Figure 32) shows the fuel cooler with its components.
TIM-ID: 0000035952 - 002

64 | Fuel System | MS13021/03E 2013-02

 Figure 32: Fuel cooler
1 Mounting bracket 3 Heat exchanger a Fuel
2 Fuel inlet connection 4 Fuel outlet connection b Air

Technical data
• Heat exchanger made from pressure- and heat-resistant aluminum
• Max. operating temperature: 150 °C (302 °F)
• Max. operating pressure: 10 bar dynamic
• Easy installation and simple maintenance

Benefits
• Increases plant safety due to reduction of fuel temperature in the day tank
• Reduces need for additional coolant, therefore, reducing costs

Function
The fuel cooler is located in the fuel return line between engine and fuel tank. The fuel cooler is mount-
ed on the coolant cooler.
The hot fuel (a) flows through the fuel inlet connection (2) into the heat exchanger (3). Air (b) drawn by
the coolant cooler fan across an aluminum matrix dissipates heat from the fuel as it passes through the
TIM-ID: 0000035952 - 002

heat exchanger. The air-cooled fuel then flows to the fuel tank via the fuel outlet connection (4).

MS13021/03E 2013-02 | Fuel System | 65

 6 Air System
6.1 Air system
The air system provides the engine with filtered, cooled air for the combustion process.
The figure shows the air system of an engine-generator set with a 12 V 1600 Gx0 engine. The figure is
also valid for an engine-generator set with an 8 or 10 V 1600 Gx0 engine.

Figure 33: Air system

1 Charge-air intake neck 3 Compressor housing KGS Engine free end
2 Compressor housing outlet a Charge-air

Technical data
• Air-to-air charge-air cooling with cooler
• Intake air filters

Benefits
• Optimum load application characteristics
TIM-ID: 0000036205 - 001

• Low fuel consumption

Function
The turbine wheel and the compressor wheel of the turbocharger are positioned on one shaft. The com-
pressor wheel in the compressor housing (3) draws air over an intake pipe from the air filter and com-
presses it. The compressed air flows from the compressor housing outlet (2) through the charge-air
pipe to the cooler.

66 | Air System | MS13021/03E 2013-02

 The cooler (→ Page 78) cools the charge-air in load operation, thereby, allowing optimum operational
behavior of the engine to be achieved. The cooled charge-air flows through the charge-air pipe from the
cooler via the charge-air intake neck (1) to the inlet ducts of the cylinder head where it is consumed
during fuel consumption.
TIM-ID: 0000036205 - 001

MS13021/03E 2013-02 | Air System | 67

 6.2 Air filter
The air filters clean the incoming air used for combustion to prevent internal damage to major compo-
nents.
The figure shows the air filter.

Figure 34: Air filter

1 Air filter housing 3 Filter service indicator
2 High torque hose clamp 4 Elbow to engine air intake

Technical data
• Single-stage engine air filter operating in light to medium dust conditions
• Non-metallic, non-corrosive, tough materials
• Air filter housing and filter media as a unit
• Direct, vertical installation

Benefits
• Compact design, vibration-resistant
• Improved reliability and durability with reduced weight and cost
TIM-ID: 0000036212 - 002

• Mounted filter service indicator

• Flexible, easy installation
• Easy and fast service
• Completely disposable

Function
Through the inlet, air is inducted into the air filter housing (1). The air flows through the filter media
from outside to inside and then flows to the engine via intake elbow (4) and engine air intake. Dust
particles suspended in the air are retained by the filter media.

68 | Air System | MS13021/03E 2013-02

 Filter service indicator
The engine-generator is equipped with a filter service indicator (3) on the intake elbow. The filter service
indicator signals when filter should be replaced.
TIM-ID: 0000036212 - 002

MS13021/03E 2013-02 | Air System | 69

 7 Exhaust System
7.1 Exhaust system
The figure shows the exhaust system of an engine-generator set with a 12 V 1600 Gx0 engine. The fig-
ure is also valid for an engine-generator set with a 10 V 1600 Gx0 engine.

Figure 35: Exhaust system

1 Exhaust manifold 3 Turbine housing a Exhaust gas
2 Turbocharger outlet 4 Exhaust turbocharger KGS Engine free end

Technical data
• Single-stage exhaust turbocharging with two turbochargers

Benefits
• Low exhaust emissions
• Straight forward connection to external exhaust gas system
• High torque at low speeds
TIM-ID: 0000036208 - 001

• Optimum load application characteristics

• Low fuel consumption

Function
The exhaust gases flow from the combustion chambers via exhaust manifolds (1) to the exhaust turbo-
chargers (4).

70 | Exhaust System | MS13021/03E 2013-02

 The exhaust gas rushing into the turbine housing (3) drives the turbine wheel of the rotor assembly of
the exhaust turbocharger, which consists of the turbine wheel and the compressor wheel mounted on
one common shaft. In doing so, the exhaust flow provides the mechanical power to compress the com-
bustion air. The exhaust gas is routed from the turbocharger outlet (2) via the exhaust pipework to the
atmosphere.

Available options
• Exhaust elbows
• Exhaust bellows
• Exhaust silencers
TIM-ID: 0000036208 - 001

MS13021/03E 2013-02 | Exhaust System | 71

 7.2 Exhaust silencer
Exhaust silencers reduce the diesel engine exhaust gas noise level and are mounted at the end of the
exhaust pipework.
The figure shows an exhaust silencer.

Figure 36: Exhaust Silencer

1 Inlet with flange 3 Flow direction a Exhaust gas
2 Enclosure 4 Outlet with flange

Technical data
• Mounted pair
• Material: Aluminized steel, welded
• Vertical inlet and axial outlet direction
• Noise reduction: 10 dB(A), 30 dB(A), or 40 dB(A)
• Painted with high temperature resistant color

Benefit
• Low exhaust gas noise emission regarding to emission law
TIM-ID: 0000036502 - 001

Function
The silencers are mounted in the exhaust pipework of the engine in each of the two lines.
The exhaust gas (a) is routed from the turbocharger outlet via the exhaust pipework and the intake (1)
into the silencer (2). The reduction of convection heat is ensured by internal insulation of the silencers.
The muffled exhaust gas leaves the silencers through the outlet (4) and is piped to the atmosphere.
Different purposes need diverse attenuation values:
• Industrial – with 10 dB(A) noise reduction
• Critical – with 30 dB(A) noise reduction
• Hospital – with 40 dB(A) noise reduction
72 | Exhaust System | MS13021/03E 2013-02
 8 Lube Oil System
8.1 Lube oil extraction pump – Mounting location
The figure shows the mounting location of the lube oil extraction pump.

Figure 37: Lube oil extraction pump – Mounting location

1 Lube oil extraction pump 2 Connection to oil drain
TIM-ID: 0000035948 - 002

MS13021/03E 2013-02 | Lube Oil System | 73

 8.2 Lube oil extraction pump
The lube oil extraction pump (also referred to as "semi-rotary hand pump") is a vane pump and provides
a simple mechanical method to remove the oil from the crankcase during maintenance.
The figure shows a lube oil extraction pump and, in detail, the cross-section of the vane pump housing.

Figure 38: Lube oil extraction pump

1 Pump hand lever 5 Assembly eyes c Valve plate
2 Vane pump housing 6 Pump outlet to used-oil d Suction chamber
3 Connection to oil drain tank e Suction valve seat
4 Pump intake from oil pan a Vane
b Pressure chamber

Technical data
• Mechanical, semi-rotary hand pump
• Vertical installation position, suction connection at bottom

Benefit
• Electric pump for servicing not needed
TIM-ID: 0000000136 - 009

Function
The lube oil extraction pump is a semi-rotary hand pump. The inner chamber of the pump is divided into
suction chamber (d) and pressure chamber (b) by the vane (a). The suction chamber is subdivided into
two chambers by the suction valve seat (e). All chambers are interconnected by the valve plates (c).
Before using the pump, a used-oil tank has to be established and connected to the pump outlet (6), and
the attached valve has to be opened to allow the oil flowing through the pipe.

74 | Lube Oil System | MS13021/03E 2013-02

 When the pump hand lever (1) is actuated, the vane in the housing (2) moves to alternately increase the
volume of one suction chamber and decrease the volume of the opposite chamber. A depression is cre-
ated in the expanding chamber. The valve plate in the suction valve seat is lifted and allows oil from the
rear oil pan drain into the chamber via the pump intake (4). In the decreasing suction chamber, the
valve plate in the suction valve seat is closed and the valve plate in the vane is opened. The oil is forced
into the pressure chamber and from there via the pump outlet (6) to the used-oil tank.
TIM-ID: 0000000136 - 009

MS13021/03E 2013-02 | Lube Oil System | 75

 9 Cooling System
9.1 Cooling system
The cooling system on an engine-generator set with an air-to-air charge-air cooled engine consists of
engine coolant cooling and charge-air cooling.
Engine coolant and charge-air are cooled by means of a cooler (→ Page 78).
The figure shows the engine coolant flow (engine-side) of an engine-generator set with a 12 V 1600 Gx0
engine. The figure is also valid for an engine-generator set with an 8 or 10 V 1600 Gx0 engine.

Figure 39: Engine coolant circuit

1 Outlet to cooler 5 Cylinder liner a Engine coolant
2 Oil cooler 6 Inlet from cooler KGS Engine free end
3 Cylinder head 7 Coolant pump
4 Crankcase 8 Thermostat

Technical data
• Single-circuit cooling system
TIM-ID: 0000036336 - 002

• Thermostat-controlled engine coolant circuit

• Air-to-air charge-air cooling

Benefits
• Complete system solution with cooler, including fan drive, fan and piping

Function
The engine coolant circuit is a high-temperature circuit (HT).
The engine coolant is cooled in the same-named core of the cooler (→ Page 78).

76 | Cooling System | MS13021/03E 2013-02

 The coolant pump (7) is assembled on the engine. It pumps the cooled engine coolant (a) from the core
via the coolant pipe to the inlet (6) through the engine. There, one part of the coolant is routed through
the oil cooler (2), a second part bypasses the oil cooler. The combined flows enter the coolant duct of
the crankcase (4). In the crankcase, the coolant flows to the cylinders in the cylinder head (3), around
the cylinder liners (5) from bottom to top and overflows into the cylinder head (3). There, it flows
through the coolant spaces and coolant ducts of the cylinder head and arrives at the thermostat (8).
The thermostat (8) leads the engine coolant directly to the engine coolant pump (7) when the engine is
cold.
Bypassing the cooler allows the engine, lube oil and engine coolant to reach operating temperature
quickly.
The thermostat (8) diverts the engine coolant via the outlet (1) and the coolant pipe to the cooler when
the engine is under load (warm engine). Re-cooled engine coolant coming from the cooler (engine cool-
ant core) then returns to the engine coolant pump (7).
Drain plugs are provided at the lowest points of the engine coolant circuit.
Coolant preheating is provided by an optional engine coolant preheater (→ Page 80).
The cooler also cools the charge-air. For a description of the charge-air cooling, refer to (→ Page 66).
TIM-ID: 0000036336 - 002

MS13021/03E 2013-02 | Cooling System | 77

 9.2 Coolant cooler
The coolant cooler (also referred to as "radiator") is a combined cooler for the engine coolant and the
charge-air.
The figure shows the coolant cooler.

Figure 40: Cooler

1 Pressure cap 7 Complete fan guard 13 Vent line
2 Level sensor 8 Charge-air pipes from en- 14 Core (engine coolant)
3 Expansion tank gine to cooler a Charge-air
4 Core (charge-air) 9 Engine coolant pipe from b Engine coolant
5 Core face guard cooler to engine
6 Fan 10 Charge-air pipe from cool-
er to engine
11 Engine coolant pipe from
engine to cooler
12 Expansion pipe

Technical data
For technical data, refer to the specification sheet (→ Page 9).
TIM-ID: 0000040195 - 001

Benefits
• Thermostat control ensures that optimum coolant and engine temperatures are reached quickly
• Charge-air cooling during load operation

Function
The cooler consists of two cores, one for the engine coolant cooling and one for the charge-air cooling.
The engine coolant (b) is cooled in the engine coolant core (14) of the cooler by means of fan (6) circu-
lation.

78 | Cooling System | MS13021/03E 2013-02

 From the engine coolant core (14), the coolant is pumped via the coolant pipe (9) to the engine and
cools the cylinders during work. Depending on coolant temperature after passing the cylinders, an en-
gine-mounted thermostat routes a part of the coolant via the coolant pipe (11) back to the engine cool-
ant core (14) where the coolant is re-cooled.
The coolant expansion tank (3) is installed on the cooler at the highest point of the cooling system. It
allows compensation of coolant quantity and pressure variations. As the coolant expands with increas-
ing temperature, its pressure in the closed system increases also. The coolant expansion tank is equip-
ped with pressure overflow devices (1, 12), a vent line (13) and a level sensor (2).
The compressed air (coming via air filters and turbocharger) flows through the intake charge-air
pipes (8) to the charge-air core (4). There, the charge-air (a) is cooled by means of fan (6) circulation
during load operation. The cooled charge-air flows through outlet charge-air pipe (10) to the engine
where it is consumed during fuel combustion.
TIM-ID: 0000040195 - 001

MS13021/03E 2013-02 | Cooling System | 79

 9.3 Preheater
The engine coolant preheater (also referred to as "jacket water heater") is designed to heat and circu-
late coolant throughout the engine’s water galleries to efficiently maintain an engine at optimum start-
ing temperatures. Maintaining engine coolant temperatures ensures easy starting, reduces harmful
emissions at start-up and allows engines to go to full power without needless idling.
The figure (→ Figure 41) shows the mounting location of the engine coolant preheater and the connec-
tion of the return line from the engine.

Figure 41: Preheater – Mounting location, cooler side view

1 Connection return line 3 Return line (from engine) 5 Fill line (to engine)
(from engine) 4 Preheater
2 Shut-off cock
The figure (→ Figure 42) shows the connection of the fill line to the engine of the engine coolant pre-
heater.
TIM-ID: 0000035951 - 002

80 | Cooling System | MS13021/03E 2013-02

 Figure 42: Preheater – Mounting location, generator side view
1 Connection fill line (to en- 2 Shut-off cock 3 Fill line (to engine)
gine)
The figure (→ Figure 43) shows the engine coolant preheater.
TIM-ID: 0000035951 - 002

MS13021/03E 2013-02 | Cooling System | 81

 Figure 43: Engine coolant preheater
1 Return line (from engine) 4 Preheater 7 Fill line (to engine)
2 Shut-off cock 5 Non-return flap
3 Mounting bracket 6 Shut-off cock

Technical data
• Integrated pump for forced circulation
• Integrated thermostat
• 240 V, single phase, 50 Hz
• Power of 2.5 kW
• Flow rate of 9.5 l/min (2.5 GPM)
• Glass fiber reinforced thermoplastic
• Euro power cord for external power supply
• Ingress protection: IP 44
• CE compliant

Benefits
• Forced circulation of coolant eliminates hotspots and provides uniform engine heating
• Reduced outlet temperature extends hose life and reduces heater maintenance
• Reduced electrical consumption on engine startup
TIM-ID: 0000035951 - 002

• Compact design requires minimal material, space, and time for mounting
• Simple to install

82 | Cooling System | MS13021/03E 2013-02

 Function
The preheater (4) is powered by an external power supply. Upon energizing the preheater, engine cool-
ant is circulated via the integrated pump: The coolant flows through the return line (1) from the engine
to the preheater and leaves the preheater through the fill line (7) to the engine. The integrated thermo-
stat cycles the heating element on and off based on coolant temperature. When the predefined coolant
temperature is reached, the thermostat causes the heating element and the pump to stop working.
Heating element and pump begin to work again when the thermostat detects a coolant temperature
below the predefined value.
TIM-ID: 0000035951 - 002

MS13021/03E 2013-02 | Cooling System | 83

 10 Electrical System
10.1 Starter batteries
Starter batteries are necessary to start the engine-generator set. The highest cranking capacity for en-
gine-generator sets is ensured by using a combination of two 12 VDC batteries arranged in a series-
parallel combination. This will provide the necessary 24 V system voltage.
The figure (→ Figure 44) shows the mounting location of the starter batteries.

Figure 44: Starter batteries – Mounting location

1 Starter batteries 2 Mounting rack
The figure (→ Figure 45) shows the lead-acid starter batteries with six cells.
TIM-ID: 0000035945 - 002

84 | Electrical System | MS13021/03E 2013-02

 Figure 45: Starter battery
1 Battery terminal 3 Cell cap
2 Handhold 4 Battery block

Technical data
• Set of two 12 V lead-acid batteries
• Capacity per battery: 100 Ah
• Cold cranking amperes at -18 °C (0 °F): 760 A
• Very low self-discharge rate

Benefits
• Immediate start of the engine-generator set due to high quality batteries
• Large tolerance for low ambient temperatures
• Automatic recharge by the engine-driven charging system
• Best battery performance and longest battery life with optional battery charger control system
• Easy installation and maintenance
• Rechargeable

Function
TIM-ID: 0000035945 - 002

The batteries are connected to the engine starter. If start of the engine-generator set is requested, the
control panel commands the starter to operate. The starter takes up DC power from the batteries to
start the engine-generator set.
Once the engine is running, the power supply from the batteries stops. The lost capacity (discharge
amount) will be automatically recharged by the engine-driven battery-charging generator during engine
operation.
All starter batteries in an engine-generator set must be of the same model (equal size and cold cranking
amperes).

MS13021/03E 2013-02 | Electrical System | 85

 10.2 Battery charger
The battery charger (a DC power supply) monitors and charges the batteries.
The battery charger for engine-generator sets with control version 1 (includes terminal box) is supplied
loose. With control versions 2 to 4 (include control panel DGC-2020), the battery charger is mounted in
the control cabinet.
The figure shows the battery charger for engine-generator sets.

Figure 46: Battery charger

1 Mounting DIN rail 4 DC output -V 7 AC neutral input
2 Battery charger box 5 LED indicator for DC ON 8 AC phase input
3 DC output +V (power on)
6 Ground
TIM-ID: 0000036211 - 001

86 | Electrical System | MS13021/03E 2013-02

 Technical data
• Protection:
– Short circuit protection
– Overvoltage protection 120 to 150 % of rated DC output voltage (30 to 36 VDC)Protection type:
shutdown output voltage; re-power on to recover
– Overload protection 105 to 150 % of rated output power Protection type: constant current limiting;
auto recovery after fault condition is removed
– Overtemperature protection 100±5 °C (212±9 °F), TSW1, detect on heat sink of power transistor-
Protection type: shutdown output voltage; auto recovery after temperature goes down
• Installed on DIN rail TS35/7.5 or 15
• LED indication for POWER ON
• Cooling by free air convection
• Worldwide operating voltage and frequency ranges
• Safety standards UL508; UL60950-1; TUV EN60950-1 approved
• EMC standards EN55011; EN55022 Class B; EN55024; EN61000-3-2,3; EN61000-4-2,3,4,5,6,8,11;
ENV50204
• Lightning transient immunity to EN61000-6-2 (EN50082-2) heavy industrial
Operating power Values
DC output voltage: 24 V nominal
Rated current: 10 A
Rated power: 240 W
Set time / rise time / hold up time @100 % load and 230 VAC: 800 ms / 40 ms / 24 ms
AC input voltage range: 85 to 264 VAC
Built in power factor correction (PFC) circuit @100 % load and 0.96
230 VAC:

Environmental condition Values

Temperature: Operating @100 % load and 230 VAC: -10 to 55 °C (14 to 131 °F)
Operating @60 % load and 230 VAC: -10 to 70 °C (14 to 158 °F)
Storage: -20 to 85 °C (-4 to 185 °F)
Relative humidity: Operating: 20 to 90 %, non-condensing
Storage: 10 to 95 %
Temperature coefficient: ±0.03 %/°C at 0 to 50 °C (32 to 122 °F)
Vibration: 10 to 500 Hz, 2 G for 10 min./1 cycle, 60 min. each axis
TIM-ID: 0000036211 - 001

MS13021/03E 2013-02 | Electrical System | 87

 10.3 Circuit breaker
Circuit breaker is an electrical switch designed to protect electrical systems from damage caused by
overloads and short circuits. Circuit breakers open (break) and close a circuit by non-automatic means
and open (break) the circuit automatically on a pre-determined overcurrent. Electronic trip case circuit
breakers use an electronic trip system to signal the circuit breaker to open automatically.
The figure (→ Figure 47) shows the mounting location of the circuit breaker cabinet.

Figure 47: Circuit breaker cabinet – Mounting location

1 Circuit breaker cabinet
The figure (→ Figure 48) shows a circuit breaker of type T7M, motorized, with trip unit PR231/P LS/I.
TIM-ID: 0000035864 - 002

88 | Electrical System | MS13021/03E 2013-02

 Figure 48: Circuit breaker T7M, motorized, with trip unit PR231/P LS/I
1 Terminal box 7 Signal: springs charged or I Protection I field
2 Trip unit discharged S Protection S field
3 Signal: circuit breaker 8 Lever to manually charge F Dip switch for network fre-
open "O" or closed "I" closing springs quency
4 Switch manual closing 9 Nameplate of circuit N Dip switch for neutral set-
5 Test push button/mechan- breaker ting
ical trip indicator R Rating plug
6 Switch manual opening T Socket for test unit TT1
L Protection L field

Technical data
• Brand: ABB, 100 % rated current, 690 V, automatic circuit breakers
• Overcurrent protection with electronic trip unit
• Molded case
• Compact enclosure sheet steel structure
• Double insulation of the live parts and total segregation between phases
• Main standards: IEC 60947-2, IEC 61000, IEC 60068
• Compliant with: LVD 2006/95/CE (replaces LVD 73/23 EEC), EMC 89/336 EEC
Breaker models
TIM-ID: 0000035864 - 002

• Tmax T6 with trip unit PR221/DS LS/I

– rated current of 800 A
– 3- or 4-pole
– manually operated or electrically operated (motorized)
• Tmax T7M with trip unit PR231/P LS/I
– rated current of 1000 A, 1250 A or 1600 A
– 3- or 4-pole
– manually operated or electrically operated (motorized)

MS13021/03E 2013-02 | Electrical System | 89

 Benefits
• High interrupting ratings and field-installable accessories in a small package
• Individual solutions for control and protection
• Extremely reliable to withstand high dynamic and thermal stresses

Function
The circuit breakers can be manually operated, by the operating lever or the rotary handle (direct or
transmitted), and electrically operated (optional).

Electrically operated (motorized) circuit breakers

The circuit breakers are operated using pre-charged springs. The springs can be charged manually with
the lever (8) or using a motor (option). The opening springs are charged automatically during the closing
operation.
Closing and opening operations can be initiated by remote control or by switches (4) and (6) on the
front cover. The front cover of the circuit breakers is marked open "O" and closed "I" (3) and is equip-
ped with a signal for springs charged or discharged (7). An indicator (5) is signaling mechanical release
of overcurrent tripped.
The following operating cycles are possible without recharging the springs:
• Starting with the circuit breaker open (0) and the springs charged: closing-opening (C-O)
• Starting with the circuit breaker closed (I) and the springs charged: opening-closing-opening (O-C-O)

Manually operated circuit breakers

Manually operated circuit breakers have a single operating handle that acts directly through the operat-
ing mechanism against the contact blades. Multi-pole circuit breakers have a common trip bar for posi-
tive action of all poles on manual and automatic operation. These circuit breakers have a trip‑free
mechanism that allows them to trip even though the operating handle may be restricted (by a handle
operating mechanism or padlock attachment) in the I (ON) position.
If not restricted, the operating handle moves to a position between I (ON) and O (OFF) when the circuit
breaker is tripped.
The front cover of the manually operated circuit breakers is marked with standard ON/OFF and interna-
tional I/O markings to indicate handle position. In addition, the I (ON) portion of the circuit breaker han-
dle is color coded green.

Undervoltage release
The undervoltage release is triggered by emergency stop on control panel. If an emergency stop is
caused, the undervoltage release stops the engine-generator set and opens the circuit breaker.
With the undervoltage release de-energized, it is not possible to close the circuit breaker or the main
contacts.

Electronic trip system

The trip system causes the circuit breaker to open automatically under overload or short-circuit. Elec-
TIM-ID: 0000035864 - 002

tronic trip circuit breakers give the customer more versatility to achieve coordination with features such
as adjustable instantaneous pickup and high withstand ratings.
The trip system consists of a set of current transformers (CTs or sensors) to sense current, a trip unit to
evaluate the current, and a tripping solenoid (tripping coil) to trip the circuit breaker. The tripping coil is
a flux transfer solenoid that requires no external power source. All protective functions are completely
fault powered.
Trip units are designed to protect power circuits and loads.

90 | Electrical System | MS13021/03E 2013-02

 Function
The electronic trip units PR221/DS-LS/I and PR231/P LS/I offers the following protection functions
together with a wide combination of thresholds and trip times:
L Overload
S Selective short-circuit; selectable as an alternative to protection function I
I Adjustable instantaneous short-circuit; selectable as an alternative to protection function S
DIP-switches on the trip unit allow the user to set the proper overcurrent required in the electrical sys-
tem. If current exceeds a set value for longer than its set time delay, the trip system opens the circuit
breaker. Alarms may be programmed for remote indications. Measurements of current, voltage, fre-
quency, power and power quality optimize continuity of service and energy management.

PR221DS trip unit, version LS/I

The PR221DS LS/I trip unit provides protection functions against overload L and short-circuit S or I. By
moving the dedicated dip-switch, protection S or protection I can be chosen.
There is a single adjustment for the phases and the neutral. It is possible to select the protection
threshold OFF, 50 % or 100 % directly from the front of the trip unit by means of the specific dip switch.
The opening solenoid is housed internally and therefore, by not using the right-hand slot of the circuit-
breaker, all the auxiliary contacts available can be used.

PR231/P trip unit, version LS/I

The PR231/P trip unit is the basic trip unit for Tmax T7. PR231/P LS/I provides protection functions
against overload L and short-circuit S or I. By moving the dedicated dip-switch, protection S or protec-
tion I can be chosen.
Setting the trip parameters is made directly on the front of the trip unit by means of dip switches. There
is only one for the phases and the neutral, so it is possible to set the protection threshold at 50 % or at
100 % of the phase protection.
To guarantee protection of the installation, it is necessary to select the rated network frequency
(50/60 Hz) by means of the special dip-switch. Interchangeability of PR231/P can optionally be re-
quested.
TIM-ID: 0000035864 - 002

MS13021/03E 2013-02 | Electrical System | 91

 11 Base and Mounting System
11.1 Base frame and mounting
The base frame provides support for all components of the engine-generator set.

Figure 49: Base frame with mounts – Generator side view

1 Side channel – left 4 Cooler cross member 7 Engine mounts
2 Engine rubber mounts 5 Side channel – right 8 Generator cross member
3 Lifting bracket 6 Engine cross members 9 Generator rubber mounts
The base frame is a steel structure and consists of two side channels (1, 5) and several cross members
(4, 6, 8). The cross members represent a welded structure and are welded to the side channels. The
cross members for the generator (8) are fitted with rubber mounts for the generator (9). The cross
members for the diesel engine (6) are fitted with engine mounts (7) and engine rubber mounts (2). The
cooler is mounted directly on the cooler cross member (4).

Technical data
• Welded steel structure
TIM-ID: 0000035947 - 001

• Resilient engine and generator mounting

Benefits
• One common base to facilitate engine-generator set transportation
• Easy access to all major components
• Optimization of vibrational characteristics

92 | Base and Mounting System | MS13021/03E 2013-02

12 Specification Sheets
12.1 Specification sheet DP00450D5S (exhaust optimized) .................................................................................................................. 95
12.2 Specification sheet DP00450D5S (fuel optimized) .......................................................................................................................... 99
12.3 Specification sheet DP00500D5S (exhaust optimized) .................................................................................................................. 103
12.4 Specification sheet DP00500D5S (fuel optimized) .......................................................................................................................... 107
12.5 Specification sheet DP00590D5S (exhaust optimized) .................................................................................................................. 111
12.6 Specification sheet DP00590D5S (fuel optimized) .......................................................................................................................... 115
12.7 Specification sheet DP00650D5S (exhaust optimized) .................................................................................................................. 119
12.8 Specification sheet DP00650D5S (fuel optimized) .......................................................................................................................... 123
12.9 Specification sheet DS00500D5S (fuel optimized) .......................................................................................................................... 127
12.10 Specification sheet DS00550D5S (fuel optimized) .......................................................................................................................... 131
12.11 Specification sheet DS00650D5S (fuel optimized) .......................................................................................................................... 135
12.12 Specification sheet DS00715D5S (fuel optimized) .......................................................................................................................... 139

MS13021/03E 2013-02 | Specification Sheets | 93

94 | Specification Sheets | MS13021/03E 2013-02
 12.1 Specification sheet DP00450D5S (exhaust optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
450 kVA /50 Hz /Prime (Exhaust-Optimized)
380 - 415V

(Reference DS500D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime** DP450D5S DP450D5S DP450D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 360 360 360
kVA 450 450 450
AMPS 684 650 626
skVA@30%
Voltage Dip 860 970 1060
Generator Model 572RSL7725 572RSL7725 572RSL7725
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

** Prime technical data is for an Exhaust-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Emissions - TA-Luft Certified // Power Rating
- Permissible average power output during 24 hours of
// Engine-generator set is designed and manufactured operation is approved up to 75%.
in facilities certified to standards ISO 9001:2008 and
ISO 14001:2004

// Performance Assurance Certification (PAC)

TIM-ID: 0000039722 - 002

- Engine-Generator Set Tested to ISO 8528-5 for

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 95
 2 / // / 50 Hz 450 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
TA-Luft Compliant Engine ±0.25% Voltage Regulation
100% of Rated Load - One Step
3% Maximum Harmonic Content
// Customer Interface Insulation Class H
Protection Class IP20
Smart Connect
TIM-ID: 0000039722 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

96 | | MS13021/03E 2013-02
 3 / // / 50 Hz 450 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 10V1600G10F At 100% of Power Rating: L/hr (gal/hr) 100.3 (26.5)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 76.84 (20.3)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 52.61 (13.9)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous) Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 407 (546) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 390 (103)
Heat Rejection to Coolant: kW (BTUM) 206 (11,715)
Heat Rejection to After Cooler: kW (BTUM) 83 (4,720)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 21 (1,194)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 28 (975)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 654 (23,096)

Fuel Supply Connection Size M 22x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Fuel Return Connection Size M 16x1.5 Male
Maximum Fuel Lift: m (ft) 5 (16) // Exhaust System
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 340.7 (90) **PRIME
Gas Temp. (Stack): °C (°F) 548 (1,018)
Gas Volume at Stack
Temp: m3/min (CFM) 86 (3,051)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
** Prime technical data is for an Exhaust-Optimized Prime unit.
TIM-ID: 0000039722 - 002

MS13021/03E 2013-02 | | 97
 4 / // / 50 Hz 450 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235911 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) 88.2
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039722 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

98 | | MS13021/03E 2013-02
 12.2 Specification sheet DP00450D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
450 kVA /50 Hz /Prime (Fuel-Optimized)
380 - 415V

(Reference DS500D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime ** DP450D5S DP450D5S DP450D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 360 360 360
kVA 450 450 450
AMPS 684 650 626
skVA@30%
Voltage Dip 860 970 1060
Generator Model 572RSL7725 572RSL7725 572RSL7725
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

** Prime technical data is for a Fuel-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 75%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
TIM-ID: 0000039723 - 002

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 99
 2 / // / 50 Hz 450 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Maximum Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039723 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

100 | | MS13021/03E 2013-02

 3 / // / 50 Hz 450 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 10V1600G10F At 100% of Power Rating: L/hr (gal/hr) 91.22 (24.1)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 73.43 (19.4)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 52.61 (13.9)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 407 (546) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 210 (11,942)
Heat Rejection to After Cooler: kW (BTUM) 47 (2,673)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 21 (1,194)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 24 (848)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 654 (23,096)

Fuel Supply Connection Size M 22x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Fuel Return Connection Size M 16x1.5 Male
Maximum Fuel Lift: m (ft) 5 (16) // Exhaust System
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 340.7 (90) **PRIME
Gas Temp. (Stack): °C (°F) 549 (1,020)
Gas Volume at Stack
Temp: m3/min (CFM) 68 (2,416)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
** Prime technical data is for a Fuel-Optimized Prime unit.
TIM-ID: 0000039723 - 002

MS13021/03E 2013-02 | | 101

 4 / // / 50 Hz 450 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235901 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) 88.2
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039723 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

102 | | MS13021/03E 2013-02

 12.3 Specification sheet DP00500D5S (exhaust optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
500 kVA /50 Hz /Prime (Exhaust-Optimized)
380 - 415V

(Reference DS550D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime** DP500D5S DP500D5S DP500D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 400 400 400
kVA 500 500 500
AMPS 760 722 696
skVA@30%
Voltage Dip 980 1100 1200
Generator Model 572RSL7727 572RSL7727 572RSL7727
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

** Prime technical data is for an Exhaust-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Emissions - TA-Luft Certified // Power Rating
- Permissible average power output during 24 hours of
// Engine-generator set is designed and manufactured operation is approved up to 75%.
in facilities certified to standards ISO 9001:2008 and
ISO 14001:2004

// Performance Assurance Certification (PAC)

TIM-ID: 0000039724 - 002

- Engine-Generator Set Tested to ISO 8528-5 for

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 103

 2 / // / 50 Hz 500 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
TA-Luft Compliant Engine ±0.25% Voltage Regulation
100% of Rated Load - One Step
3% Maximum Harmonic Content
// Customer Interface Insulation Class H
Protection Class IP20
Smart Connect
TIM-ID: 0000039724 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

104 | | MS13021/03E 2013-02

 3 / // / 50 Hz 500 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 10V1600G20F At 100% of Power Rating: L/hr (gal/hr) 111.7 (29.5)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 83.27 (22)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 57.53 (15.2)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 448 (601) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 390 (103)
Heat Rejection to Coolant: kW (BTUM) 222 (12,624)
Heat Rejection to After Cooler: kW (BTUM) 100 (5,687)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 46.5 (2,644)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 30 (1,059)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 654 (23,096)

Fuel Supply Connection Size M 22x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Fuel Return Connection Size M 16x1.5 Male
Maximum Fuel Lift: m (ft) 5 (16) // Exhaust System
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 340.7 (90) **PRIME
Gas Temp. (Stack): °C (°F) 540 (1,004)
Gas Volume at Stack
Temp: m3/min (CFM) 97 (3,411)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
** Prime technical data is for an Exhaust-Optimized Prime unit.
TIM-ID: 0000039724 - 002

MS13021/03E 2013-02 | | 105

 4 / // / 50 Hz 500 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235931 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) 88.3
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039724 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

106 | | MS13021/03E 2013-02

 12.4 Specification sheet DP00500D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
500 kVA /50 Hz /Prime (Fuel-Optimized)
380 - 415V

(Reference DS550D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime ** DP500D5S DP500D5S DP500D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 400 400 400
kVA 500 500 500
AMPS 760 722 696
skVA@30%
Voltage Dip 980 1100 1200
Generator Model 572RSL7727 572RSL7727 572RSL7727
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

** Prime technical data is for a Fuel-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 75%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
TIM-ID: 0000039725 - 002

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 107

 2 / // / 50 Hz 500 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Maximum Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039725 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

108 | | MS13021/03E 2013-02

 3 / // / 50 Hz 500 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 10V1600G20F At 100% of Power Rating: L/hr (gal/hr) 99.92 (26.4)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 77.97 (20.6)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 57.15 (15.1)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 448 (601) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 390 (103)
Heat Rejection to Coolant: kW (BTUM) 216 (12,283)
Heat Rejection to After Cooler: kW (BTUM) 60 (3,412)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 46.5 (2,644)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 27 (953)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 654 (23,096)

Fuel Supply Connection Size M 22x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Fuel Return Connection Size M 16x1.5 Male
Maximum Fuel Lift: m (ft) 5 (16) // Exhaust System
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 340.7 (90) **PRIME
Gas Temp. (Stack): °C (°F) 520 (968)
Gas Volume at Stack
Temp: m3/min (CFM) 75 (2,649)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
** Prime technical data is for a Fuel-Optimized Prime unit.
TIM-ID: 0000039725 - 002

MS13021/03E 2013-02 | | 109

 4 / // / 50 Hz 500 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235921 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) 88.3
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039725 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

110 | | MS13021/03E 2013-02

 12.5 Specification sheet DP00590D5S (exhaust optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
590 kVA /50 Hz /Prime (Exhaust-Optimized)
380 - 415V

(Reference DS650D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime** DP590D5S DP590D5S DP590D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 472 472 472
kVA 590 590 590
AMPS 896 852 821
skVA@30%
Voltage Dip 1050 1200 1750
Generator Model 572RSL7729 572RSL7731 572RSL7731
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

** Prime technical data is for an Exhaust-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Emissions - TA-Luft Certified // Power Rating
- Permissible average power output during 24 hours of
// Engine-generator set is designed and manufactured operation is approved up to 75%.
in facilities certified to standards ISO 9001:2008 and
ISO 14001:2004

// Performance Assurance Certification (PAC)

TIM-ID: 0000039726 - 002

- Engine-Generator Set Tested to ISO 8528-5 for

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 111

 2 / // / 50 Hz 590 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Maximum Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
TA-Luft Compliant Engine ±0.25% Voltage Regulation
100% of Rated Load - One Step
3% Maximum Harmonic Content
// Customer Interface Insulation Class H
Protection Class IP20
Smart Connect
TIM-ID: 0000039726 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

112 | | MS13021/03E 2013-02

 3 / // / 50 Hz 590 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 12V1600G10F At 100% of Power Rating: L/hr (gal/hr) 127.9 (33.8)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 97.27 (25.7)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 68.13 (18)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 524 (703) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 225 (12,795)
Heat Rejection to After Cooler: kW (BTUM) 121 (6,881)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 52.5 (2,985)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 36 (1,271)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 191 (6,733)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

**PRIME
Gas Temp. (Stack): °C (°F) 466 (871)
Gas Volume at Stack
Temp: m3/min (CFM) 96 (3,390)
Maximum Allowable
TIM-ID: 0000039726 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

** Prime technical data is for an Exhaust-Optimized Prime unit.

MS13021/03E 2013-02 | | 113

 4 / // / 50 Hz 590 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235971 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039726 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

114 | | MS13021/03E 2013-02

 12.6 Specification sheet DP00590D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
590 kVA /50 Hz /Prime (Fuel-Optimized)
380 - 415V

(Reference DS650D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime ** DP590D5S DP590D5S DP590D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 472 472 472
kVA 590 590 590
AMPS 896 852 821
skVA@30%
Voltage Dip 1050 1200 1750
Generator Model 572RSL7729 572RSL7731 572RSL7731
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

** Prime technical data is for an Exhaust-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 75%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039727 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 115

 2 / // / 50 Hz 590 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilate
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Maximum Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039727 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

116 | | MS13021/03E 2013-02

 3 / // / 50 Hz 590 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 12V1600G10F At 100% of Power Rating: L/hr (gal/hr) 118.1 (31.2)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 91.98 (24.3)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 63.59 (16.8)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 524 (703) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 231 (13,136)
Heat Rejection to After Cooler: kW (BTUM) 87 (4,947)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 53.5 (3,042)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 36 (1,271)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 194 (6,861)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

**PRIME
Gas Temp. (Stack): °C (°F) 482 (900)
Gas Volume at Stack
Temp: m3/min (CFM) 90 (3,178)
Maximum Allowable
TIM-ID: 0000039727 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

** Prime technical data is for a Fuel-Optimized Prime unit.

MS13021/03E 2013-02 | | 117

 4 / // / 50 Hz 590 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235961 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039727 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

118 | | MS13021/03E 2013-02

 12.7 Specification sheet DP00650D5S (exhaust optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
650 kVA /50 Hz /Prime (Exhaust-Optimized)
380 - 415V

(Reference DS715D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime** DP650D5S DP650D5S DP650D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 520 520 520
kVA 650 650 650
AMPS 988 938 904
skVA@30%
Voltage Dip 1450 1600 1750
Generator Model 573RSL7733 573RSL7733 573RSL7733
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

** Prime technical data is for an Exhaust-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Emissions - TA-Luft Certified // Power Rating
- Permissible average power output during 24 hours of
// Engine-generator set is designed and manufactured operation is approved up to 75%.
in facilities certified to standards ISO 9001:2008 and
ISO 14001:2004

// Performance Assurance Certification (PAC)

TIM-ID: 0000039728 - 002

- Engine-Generator Set Tested to ISO 8528-5 for

Transient Response
- Verified product design, quality and performance integrity
- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 119

 2 / // / 50 Hz 650 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
TA-Luft Compliant Engine ±0.25% Voltage Regulation
100% of Rated Load - One Step
3% Maximum Harmonic Content
// Customer Interface Insulation Class H
Protection Class IP20
Smart Connect
TIM-ID: 0000039728 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

120 | | MS13021/03E 2013-02

 3 / // / 50 Hz 650 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 12V1600G20F At 100% of Power Rating: L/hr (gal/hr) 140.8 (37.2)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 104.1 (27.5)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 71.54 (18.9)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous) Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 576 (772) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 250 (14,217)
Heat Rejection to After Cooler: kW (BTUM) 121 (6,881)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 58.4 (3,321)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 38 (1,335)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 212 (7,490)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

**PRIME
Gas Temp. (Stack): °C (°F) 470 (878)
Gas Volume at Stack
Temp: m3/min (CFM) 102 (3,602)
Maximum Allowable
TIM-ID: 0000039728 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

** Prime technical data is for an Exhaust-Optimized Prime unit.

MS13021/03E 2013-02 | | 121

 4 / // / 50 Hz 650 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235991 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Power
Generation Distributor for altitude derations.
Temperature: Consult your local MTU Onsite Energy Power
Generation Distributor for temperature derations.
TIM-ID: 0000039728 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

122 | | MS13021/03E 2013-02

 12.8 Specification sheet DP00650D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
650 kVA /50 Hz /Prime (Fuel-Optimized)
380 - 415V

(Reference DS715D5S-Fuel Optimized for Standby Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Prime ** DP650D5S DP650D5S DP650D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 520 520 520
kVA 650 650 650
AMPS 988 938 904
skVA@30%
Voltage Dip 1450 1600 1750
Generator Model 573RSL7733 573RSL7733 573RSL7733
Temp Rise 125 °C/40 °C 125 °C/40 °C 125 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

** Prime technical data is for a Fuel-Optimized Prime unit.

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 75%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039729 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 123

 2 / // / 50 Hz 650 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 125 °C Maximum Prime Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039729 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

124 | | MS13021/03E 2013-02

 3 / // / 50 Hz 650 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU **PRIME

Model** 12V1600G20F At 100% of Power Rating: L/hr (gal/hr) 129.8 (34.3)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 99.92 (26.4)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 69.64 (18.4)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 **PRIME
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp)** 576 (772) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 236 (13,421)
Heat Rejection to After Cooler: kW (BTUM) 104 (5,914)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 59.4 (3,378)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 **PRIME
Aspirating: *m3/min (SCFM) 48 (1,695)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 216 (7,618)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

**PRIME
Gas Temp. (Stack): °C (°F) 483 (901)
Gas Volume at Stack
Temp: m3/min (CFM) 126 (4,450)
Maximum Allowable
TIM-ID: 0000039729 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

** Prime technical data is for a Fuel-Optimized Prime unit.

MS13021/03E 2013-02 | | 125

 4 / // / 50 Hz 650 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235981 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Prime Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Prime power ratings apply to installations where utility power
C/F C/F C/F is unavailable or unreliable. At varying load, the number of
generator set operating hours is unlimited. A 10% overload
capacity is available for one hour in twelve. Ratings are in
accordance with ISO 8528-1, ISO 3046-1, BS 5514, AS 2789,
and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039729 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

126 | | MS13021/03E 2013-02

 12.9 Specification sheet DS00500D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
500 kVA /50 Hz /Standby (Fuel-Optimized)
380 - 415V

(Reference DP450D5S-Fuel Optimized and DP450D5S-Exhaust Optimized for Prime Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Standby DS500D5S DS500D5S DS500D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 400 400 400
kVA 500 500 500
AMPS 760 722 696
skVA@30%
Voltage Dip 860 1100 1200
Generator Model 572RSL7725 572RSL7725 572RSL7727
Temp Rise 150 °C/40 °C 150 °C/40 °C 150 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 85%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039730 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 127

 2 / // / 50 Hz 500 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 150 °C Maximum Standby Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039730 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

128 | | MS13021/03E 2013-02

 3 / // / 50 Hz 500 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU STANDBY

Model 10V1600G70F At 100% of Power Rating: L/hr (gal/hr) 99.9 (26.4)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 78 (20.6)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 56.8 (15)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 STANDBY
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp) 448 (601) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 390 (103)
Heat Rejection to Coolant: kW (BTUM) 216 (12,283)
Heat Rejection to After Cooler: kW (BTUM) 60 (3,412)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 47.9 (2,724)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical

Electric Volts DC 24 // Air Requirements

Cold Cranking Amps Under -17.8 °C (0 °F) 1,000
STANDBY
Aspirating: *m3/min (SCFM) 27 (953)
// Fuel System Air Flow Required for Rad.
Cooled Unit: *m3/min (SCFM) 654 (23,096)
Fuel Supply Connection Size M 22x1.5 Male
Fuel Return Connection Size M 16x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Maximum Fuel Lift: m (ft) 5 (16)
Recommended Fuel see MTU Fluids & Lubrication Spec. // Exhaust System
Total Fuel Flow: L/hr (gal/hr) 340.7 (90)
STANDBY
Gas Temp. (Stack): °C (°F) 520 (968)
Gas Volume at Stack
Temp: m3/min (CFM) 75 (2,649)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
TIM-ID: 0000039730 - 002

MS13021/03E 2013-02 | | 129

 4 / // / 50 Hz 500 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235941 | 1/12| VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Standby Full Load
Level 0: Open Power Unit (dBA) 88.3
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Standby ratings apply to installations served by a reliable
C/F C/F C/F utility source. The standby rating is applicable to varying
loads for the duration of a power outage. No overload
capability for this rating. Ratings are in accordance with
ISO 8528-1, ISO 3046-1, BS 5514, AS 2789, and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039730 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: North & Central Europe / Mediterranean / CIS / Middle East / Africa / MTU Onsite Energy / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
MTU Onsite Energy / 1, Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6264 3841 / [email protected]
// North America / Latin America / MTU Onsite Energy Corporation / 100 Power Drive / Mankato, Minnesota 56001 / USA / Phone + 1 507 385 8629 /
Fax + 1 507 625 2968 / [email protected]

130 | | MS13021/03E 2013-02

 12.10 Specification sheet DS00550D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
550 kVA /50 Hz /Standby (Fuel-Optimized)
380 - 415V

(Reference DP500D5S-Fuel Optimized and DP500D5S-Exhaust Optimized for Prime Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Standby DS550D5S DS550D5S DS550D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 440 440 440
kVA 550 550 550
AMPS 836 794 765
skVA@30%
Voltage Dip 980 1100 1200
Generator Model 572RSL7727 572RSL7727 572RSL7729
Temp Rise 150 °C/40 °C 150 °C/40 °C 150 °C/40 °C
Connection 4 LEAD HI WYE 4 LEAD HI WYE 4 LEAD HI WYE

* Power available up to 40°C / 400 m

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 85%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039731 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 131

 2 / // / 50 Hz 550 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 10V1600 Diesel Engine
- 17.5 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Engine-generator resilient mounted
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 150 °C Maximum Standby Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039731 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

132 | | MS13021/03E 2013-02

 3 / // / 50 Hz 550 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU STANDBY

Model 10V1600G80F At 100% of Power Rating: L/hr (gal/hr) 109.4 (28.9)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 82.9 (21.9)
Arrangement 10-V At 50% of Power Rating: L/hr (gal/hr) 62.5 (16.5)
Displacement: L (Cu In) 17.5 (1,068)
Bore: cm (in) 12.2 (4.8)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 STANDBY
Engine Governor Electronic Isochronous) Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp) 493 (661) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.2 (0.8)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 390 (103)
Heat Rejection to Coolant: kW (BTUM) 227 (12,909)
Heat Rejection to After Cooler: kW (BTUM) 75 (4,265)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 51.6 (2,934)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 61 (16) Radiator Coolant Capacity: L (gal) 39 (10,3)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 STANDBY
Aspirating: *m3/min (SCFM) 29 (1,017)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 654 (23,096)

Fuel Supply Connection Size M 22x1.5 Male * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)
Fuel Return Connection Size M 16x1.5 Male
Maximum Fuel Lift: m (ft) 5 (16) // Exhaust System
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 340.7 (90) STANDBY
Gas Temp. (Stack): °C (°F) 540 (1,004)
Gas Volume at Stack
Temp: m3/min (CFM) 83 (2,924)
Maximum Allowable
Back Pressure: kPa (in. H20) 15 (60.2)
TIM-ID: 0000039731 - 002

MS13021/03E 2013-02 | | 133

 4 / // / 50 Hz 550 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,385 x 1,875 x 1,946 mm (133.27 x 73.82 x 76.61 in) 4,047 kg (8,922 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3235951 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Standby Full Load
Level 0: Open Power Unit (dBA) 88.3
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Standby ratings apply to installations served by a reliable
C/F C/F C/F utility source. The standby rating is applicable to varying
loads for the duration of a power outage. No overload
capability for this rating. Ratings are in accordance with
ISO 8528-1, ISO 3046-1, BS 5514, AS 2789, and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039731 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: North & Central Europe / Mediterranean / CIS / Middle East / Africa / MTU Onsite Energy / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
MTU Onsite Energy / 1, Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6264 3841 / [email protected]
// North America / Latin America / MTU Onsite Energy Corporation / 100 Power Drive / Mankato, Minnesota 56001 / USA / Phone + 1 507 385 8629 /
Fax + 1 507 625 2968 / [email protected]

134 | | MS13021/03E 2013-02

 12.11 Specification sheet DS00650D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
650 kVA /50 Hz /Standby (Fuel-Optimized)
380 - 415V

(Reference DP590D5S-Fuel Optimized and DP590D5S-Exhaust Optimized for Prime Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Standby DS650D5S DS650D5S DS650D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 520 520 520
kVA 650 650 650
AMPS 988 938 904
skVA@30%
Voltage Dip 1450 1600 1750
Generator Model 572RSL7731 573RSL7733 573RSL7733
Temp Rise 150 °C/40 °C 150 °C/40 °C 150 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 85%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039732 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 135

 2 / // / 50 Hz 650 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 150 °C Maximum Standby Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039732 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

136 | | MS13021/03E 2013-02

 3 / // / 50 Hz 650 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU STANDBY

Model 12V1600G70F At 100% of Power Rating: L/hr (gal/hr) 129.8 (34.3)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 99.9 (26.4)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 69.6 (18.4)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 STANDBY
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp) 576 (772) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 236 (13,421)
Heat Rejection to After Cooler: kW (BTUM) 104 (5,914)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 59.4 (3,378)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 STANDBY
Aspirating: *m3/min (SCFM) 48 (1,695)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 216 (7,618)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

STANDBY
Gas Temp. (Stack): °C (°F) 484 (903)
Gas Volume at Stack
Temp: m3/min (CFM) 126 (4,450)
Maximum Allowable
TIM-ID: 0000039732 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

MS13021/03E 2013-02 | | 137

 4 / // / 50 Hz 650 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3236001 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Standby Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Standby ratings apply to installations served by a reliable
C/F C/F C/F utility source. The standby rating is applicable to varying
loads for the duration of a power outage. No overload
capability for this rating. Ratings are in accordance with
ISO 8528-1, ISO-3046-1, BS 5514, AS 2789, and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039732 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

138 | | MS13021/03E 2013-02

 12.12 Specification sheet DS00715D5S (fuel optimized)

A TOGNUM GROUP BRAND

DIESEL GENERATOR SET

AIR CHARGE-AIR COOLING
715 kVA /50 Hz /Standby (Fuel-Optimized)
380 - 415V

(Reference DP650D5S-Fuel Optimized and DP650D5S-Exhaust Optimized for Prime Rating Technical Data)

BENEFITS
// Low installment cost
// Best fuel consumption values
// Long maintenance intervals
// High-efficiency components
// Best-in-class reliability and availability

SYSTEM RATINGS
Standby DS715D5S DS715D5S DS715D5S

Voltage (L-L) 380V 400V 415V

Phase 3 3 3
PF 0.8 0.8 0.8
Hz 50 50 50
kW 572 572 572
kVA 715 715 715
AMPS 1086 1032 995
skVA@30%
Voltage Dip 1450 1600 2000
Generator Model 573RSL7733 573RSL7733 573RSL7733
Temp Rise 150 °C/40 °C 150 °C/40 °C 150 °C/40 °C
Connection 4 LEAD WYE 4 LEAD WYE 4 LEAD WYE

* Power available up to 40°C / 400 m

CERTIFICATIONS AND STANDARDS

// Engine-generator set is designed and manufactured // Power Rating
in facilities certified to standards ISO 9001:2008 and - Permissible average power output during 24 hours of
ISO 14001:2004 operation is approved up to 85%.

// Performance Assurance Certification (PAC)

- Engine-Generator Set Tested to ISO 8528-5 for
Transient Response
TIM-ID: 0000039733 - 002

- Verified product design, quality and performance integrity

- All engine systems are prototype and factory tested

MS13021/03E 2013-02 | | 139

 2 / // / 50 Hz 715 kVA

STANDARD FEATURES*
// The generator set complies to G2 // Permanent Magnet Generator (PMG)
// Engine-generator set tested to ISO 8528-5 for transient - Brushless, Rotating Field Generator
response - 300% Short Circuit Capability
// Accepts rated load in one step per NFPA 110 - 2/3 Pitch Windings
// All engine-generator sets are protoype and factory tested // Cooling System 50° C
// MTU Onsite Energy is a single source supplier - Integral Set-Mounted
// Global Product Support - Engine Driven Fan
// 2 Year Standard Warranty // Terminal Box
// 12V1600 Diesel Engine
- 21.0 Liter Displacement
- Common Rail Fuel Injection
- 4-Cycle
// Complete Range of Accessories

STANDARD EQUIPMENT*
// Engine // Generator

Air Cleaners NEMA MG1, IEEE and ANSI standards compliance for temperature rise
Oil Pump and motor starting
Oil Drain Extension & S/O Valve VDE 0530, IEC 34.1, BS5000, CSA C22.2-100, AS1359
Full Flow Oil Filters Sustained short circuit current of up to 300% of the rated current for
Closed Crankcase Ventilation up to 10 seconds
Jacket Water Pump Self-Ventilated
Thermostat Superior Voltage Waveform
Exhaust Manifold - Dry Digital, Solid State, Volts-per-Hertz Regulator
Blower Fan & Fan Drive No Load to Full Load Regulation
Radiator - Unit Mounted Brushless Alternator with Brushless Pilot Exciter
Electric Starting Motor - 24V 4 Pole, Rotating Field
Governor – Electronic Isochronous 150 °C Maximum Standby Temperature Rise
Base - Formed Steel 1 Bearing, Sealed
SAE Flywheel & Bell Housing Flexible Coupling
Charging Alternator - 24V Full Amortisseur Windings
Flexible Fuel Connectors 125% Rotor Balancing
Fuel System: Common Rail 3-Phase Voltage Sensing
±0.25% Voltage Regulation
100% of Rated Load - One Step
// Customer Interface 3% Maximum Harmonic Content
Insulation Class H
Smart Connect Protection Class IP20
TIM-ID: 0000039733 - 002

* Represents standard product only. Consult Factory/MTU Onsite Energy Distributor for additional configurations.

140 | | MS13021/03E 2013-02

 3 / // / 50 Hz 715 kVA

APPLICATION DATA

// Engine // Fuel Consumption

Manufacturer MTU STANDBY

Model 12V1600G80F At 100% of Power Rating: L/hr (gal/hr) 143.1 (37.8)
Type 4-Cycle At 75% of Power Rating: L/hr (gal/hr) 107.1 (28.3)
Arrangement 12-V At 50% of Power Rating: L/hr (gal/hr) 74.6 (19.7)
Displacement: L (Cu In) 21 (1,281)
Bore: cm (in) 12 (4.72)
Stroke: cm (in) 15 (5.91) // Cooling - Radiator System
Compression Ratio 17.5:1
Rated RPM 1,500 STANDBY
Engine Governor Electronic Isochronous Ambient Capacity of Radiator: °C (°F) 50 (122)
Max Power: kWm (bhp) 634 (850) Max. Restriction of Cooling Air, Intake,
Speed Regulation ±0.25% and Discharge Side of Rad.: kPa (in. H20) 0.125 (0.5)
Air Cleaner Dry Water Pump Capacity: L/min (gpm) 433 (115)
Heat Rejection to Coolant: kW (BTUM) 255 (14,501)
Heat Rejection to After Cooler: kW (BTUM) 133 (7,563)
// Liquid Capacity (Lubrication) Heat Radiated to Ambient: kW (BTUM) 68.1 (3,873)
Engine Coolant Capacity: L (gal) 65 (17,2)
Total Oil System: L (gal) 73 (19.3) Radiator Coolant Capacity: L (gal) 41 (10,8)
Coolant to Cooler Temperature: °C (°F) 95 (203)

// Electrical
// Air Requirements
Electric Volts DC 24
Cold Cranking Amps Under -17.8 °C (0 °F) 1,000 STANDBY
Aspirating: *m3/min (SCFM) 45 (1,589)
Air Flow Required for Rad.
// Fuel System Cooled Unit: *m3/min (SCFM) 803 (28,350)
Remote Cooled Applications;
Fuel Supply Connection Size M 22x1.5 Male Air Flow Required for Dissipation
Fuel Return Connection Size M 16x1.5 Male of Radiated Gen-set Heat for a
Maximum Fuel Lift: m (ft) 5 (16) Max of 25 °F Rise: *m3/min (SCFM) 247 (8,734)
Recommended Fuel see MTU Fluids & Lubrication Spec.
Total Fuel Flow: L/hr (gal/hr) 341.8 (90.3) * Air density = 1.184 kg/m3 (0.0739 lbm/ft3)

// Exhaust System

STANDBY
Gas Temp. (Stack): °C (°F) 485 (905)
Gas Volume at Stack
Temp: m3/min (CFM) 120 (4,238)
Maximum Allowable
TIM-ID: 0000039733 - 002

Back Pressure: kPa (in. H20) 15 (60.2)

MS13021/03E 2013-02 | | 141

 4 / // / 50 Hz 715 kVA

WEIGHTS AND DIMENSIONS

Drawing above for illustration purposes only, based on standard open power 400 volt engine-generator set. Lengths may vary with other voltages. Do not use for installation design. See
website for unit specific template drawings.

System Dimensions (L x W x H) Weight (dry/less tank)

Open Power Unit (OPU) 3,715 x 1,900 x 2,047 mm (146.26 x 74.80 x 80.59 in) 4,545 kg (10,020 lbs)

© MTU Onsite Energy. | Subject to alteration due to technological advances. | 3236011 | 1/12 | VMC 2012-07.
Weights and dimensions are based on open power units and are estimates only. Consult the factory for accurate weights and dimensions for your specific engine-generator set.

SOUND DATA
Unit Type Standby Full Load
Level 0: Open Power Unit (dBA) C/F
Sound data is provided at 7 m (23 ft). Engine-generator set tested in accordance with ISO 8528-10 and with infinite exhaust.

EMISSIONS DATA RATING DEFINITIONS AND CONDITIONS

NOx + NMHC CO PM // Standby ratings apply to installations served by a reliable
C/F C/F C/F utility source. The standby rating is applicable to varying
loads for the duration of a power outage. No overload
capability for this rating. Ratings are in accordance with
ISO 8528-1, ISO 3046-1, BS 5514, AS 2789, and DIN 6271.
// Deration Factor:
Altitude: Consult your local MTU Onsite Energy Distributor
for altitude derations.
Temperature: Consult your local MTU Onsite Energy
Distributor for temperature derations.
TIM-ID: 0000039733 - 002

Materials and specifications subject to change without notice.

C/F = Consult Factory/MTU Onsite Energy Distributor

// Tognum Group Companies: Europe / Mediterranean / CIS / Middle East / Africa / MTU Friedrichshafen GmbH / 88040 Friedrichshafen / Germany /
Phone + 49 7541 90 7060 / Fax +49 7541 90 7084 / [email protected] // North East Asia / South East Asia / China / Australia / Pacific /
Tognum Asia Pte. Ltd. / 1 Benoi Place / Singapore 629923 / Republic of Singapore / Phone + 65 6861 5922 / Fax + 65 6861 3615 / [email protected]
// USA / Canada / Mexico / Latin America / MTU Onsite Energy / 100 Power Drive / Mankato, MN 56001 / USA / Phone + 1 507 625 7973 / Fax + 1 507 625 2968 /
[email protected] //www.mtu-online.com

142 | | MS13021/03E 2013-02

 13 Abbreviations
13.1 Abbreviations
Abbre- Meaning Explanation
viation
AC Alternating Current The movement or flow of electric charge that period-
ically reverses direction
ADEC Advanced Diesel Engine Control Engine governor
AEM Analog Expansion Module Option for Digital Genset Controller
AL Alarm Alarm (general)
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
ATS Automatic Transfer Switch
AVR Automatic Voltage Regulation
BCI Battery Council International
BHP Brake Horse Power
BTU British Thermal Unit
CAD Computer-Aided Design
CAN Controller Area Network Data bus system, bus standard
CE Conformité Européenne Mandatory conformity mark on many products
placed on the single market in the European Eco-
nomic Area
CEM Contact Expansion Module Option for Digital Genset Controller
CFM Cubic Feet per Minute Unit for volumetric flow rate
CSA Canadian Standards Association Not-for-profit association for safety and performance
standards, including those for electrical/electronic/
industrial equipment, boilers and pressure vessels,
environmental protection, and more
CT Current Transformer
DC Direct Current
DGC Digital Genset Controller
DIN Deutsches Institut für Normung e. V. German Standardization Organization, at the same
time identifier of German standards ("Deutsche In-
dustrie-Norm")
DIP Dual In-line Package Kind of switches
DVR Digital Voltage Regulator
TIM-ID: 0000036923 - 002

ECU Engine Control Unit

EMC Electromagnetic Compatibility
EPA Environmental Protection Agency U.S. regulatory agency for implementation of federal
laws for environment protection; establishes stand-
ards that will help meet those laws.
FCR Field Current Regulation
GCB Generator Circuit Breaker
GPM Gallons Per Minute Unit for volumetric flow rate
HALT Highly Accelerated Life Tests

MS13021/03E 2013-02 | Abbreviations | 143

 Abbre- Meaning Explanation
viation
HI High Alarm: Measured value exceeds 1st maximum limit
HIHI High High Alarm: Measured value exceeds 2nd maximum limit
HMI Human Machine Interface
HP High Pressure
HP Horse Power
HT High Temperature
ICXN – Rating definition: ISO standard (continuous) power
exceedable by 10 %
IEC International Electrotechnical Committee International standards organization for all electrical,
electronic and related technologies
IEEE Institute of Electrical and Electronic Engi- International organization for the advancement of
neers technology related to electricity
IFN – Rating definition: ISO standard fuel stop power
IP Ingress Protection Classification for environmental protection for elec-
trical/electronic devices
ISO International Organization for Standardiza- International organization for publishing worldwide
tion proprietary industrial and commercial standards
KGS Kraftgegenseite Engine free end in accordance with DIN ISO 1204
KS Kraftseite Engine driving end in accordance with DIN ISO 1204
LCD Liquid Crystal Display
LED Light Emitting Diode
L.L.C. Limited Liability Company
LO LOW Alarm: Measured value lower than 1st minimum limit
LOLO Low Low Alarm: Measured value lower than 2nd minimum lim-
it
LP Low Pressure
LSM Load Sharing Module Option for Digital Genset Controller
MAU Medium Attachment Unit
MCB Main Circuit Breaker
MIL- Military Standard
STD
NEMA National Electrical Manufacturer's Associa- U.S. association for standards for electrical products
tion
NFPA National Fire Protection Association U.S. association for standards
NPT National Pipe Thread U.S. standard for tapered threads
QL Qualification Level
TIM-ID: 0000036923 - 002

OEM Original Equipment Manufacturer A company that uses a component made by a sec-
ond company in its own product, or sells the product
of the second company under its own brand.
OPU Open Power Unit An engine-generator set with no enclosure
OSHA Occupational Safety and Health Administra- A US federal agency
tion
PAC Performance Assurance Certificate MTU Onsite Energy statement of assurance
PF Power Factor
PH Phase

144 | Abbreviations | MS13021/03E 2013-02

 Abbre- Meaning Explanation
viation
PMG Permanent Magnetic Generator
PSI Pounds per Square Inch
PTO Power Take-Off
PVC Polyvinyl Chloride
RDP Remote Desktop Protocol
RMS Root Mean Square Mathematics: Effective value
RPM Revolutions Per Minute Unit of frequency (1 RPM = 1/60 Hz);
number of rotations completed in one minute around
a fixed shaft
RTC Real Time Clock
RTD Resistive Temperature Device
RTU Remote Terminal Unit Interface for Modbus
SAE Society of Automotive Engineers U.S. standardization organization
SAM Service and Application Module Diagnostic interface
SCA Supplemental Coolant Additive
SD Sensor Defect Alarm: Sensor failure
SLI Starting, Lighting, Ignition Type of starter battery
SS Safety System
TA-Luft Technische Anleitung zur Reinhaltung der German technical regulation for protection of the air
Luft (emission limits for stationary engines in Germany)
TB – Synonym for: water-to-air charge-air cooling
TD – Synonym for: air-to-air charge-air cooling
TDC Top Dead Center
UL Underwriters Laboratories Global not-for-profit organization for product safety
testing and certification
USB Universal Serial Bus
VAR Volt-Amperes Reactive Reactive power control
VAwS Verordnung über Anlagen zum Umgang mit German degree on the protection against water haz-
wassergefährdenden Stoffen ard substances
VDE Verband Der Elektrotechnik Association for Electrical, Electronic and Information
Technologies e.V.
WYE – Triangular junction
TIM-ID: 0000036923 - 002

MS13021/03E 2013-02 | Abbreviations | 145

 14 Index
14.1 Index
A Engine-generator set
Abbreviations 143 – Application groups 4
Actuators 14 – Control version 1 33
Air filter 68 – Control version 2 35
Air system 66 – Control version 3a 37
Automatic transfer switch 37 – Control version 3b 39
– Control version 4 41
B – Control versions 30
Base frame 92 – Model designation 4
Battery charger 86 Exhaust bellows 70
Exhaust elbows 70
C Exhaust silencer 72
Charge-air cooling 76 Exhaust system 70
Circuit breaker 88
F
Control cabinet 43
Control panel DGC-2020 Fuel cooler 64
– Display operations 50 Fuel prefilter
– General information 43 – Dual fuel/water separator 61
Control version 1 33 – Single fuel/water separator 58
Control version 2 35 – With water separator 56
Control version 3a 37 Fuel system 54
Control version 3b 39
G
Control version 4 41
Control versions Generator
– Overview 30 – Digital voltage regulator 19, 20, 24
Coolant cooler – General information 16
– Overview 78
I
Cooler, refer to Coolant cooler 78
Cooling system 76 Isolated operation 35
Cylinder
J
– Designation 12
Jacket water heater, refer to Preheater 80
D
L
DGC-2020
– Display operations 50 Lube oil extraction pump 74
– General information 43 – Mounting location 73
Digital voltage regulator 19, 20, 24 M
Display operations
Mounting 92
– Control panel DGC-2020 50
Dual fuel/water separator 61 P
DCL-ID: 0000001356 - 004

E Parallel operation 41
Prefilter, fuel 56
Electrical interlock circuit breakers 39
Preheater 80
Electronic trip system 88
Engine R
– Overview 10
Radiator, refer to Coolant cooler 78
Engine coolant cooling 76
Engine coolant preheater 80 S
Engine monitoring 14
Sensors 14
Engine side
Single fuel/water separator 58
– Designation 12
Smart Connect 31

146 | Index | MS13021/03E 2013-02

 Specification sheets 9
Starter batteries 84
– Charger 86

T
Technical data 9
Terminal box 33, 34
Trip unit 88

V
Voltage regulator 20, 24
DCL-ID: 0000001356 - 004

MS13021/03E 2013-02 | Index | 147