TECHNICAL DESCRIPTION

TCG 2032V16

Picture may differ from actual engine

Technical Specs – TCG2032V16 1/20

Basic technical conditions
The specified technical data is based on the assembly conditions of ISO 3046-1 and VDE 0530
including the defined deviations and tolerances.
The tolerances and conditions of all measuring equipment utilised is to be considered in favour of the
supplier.

The compliance with maintenance intervals and emissions can only be guaranteed if the "Minimum
characteristics for fuel gases" are complied with, the required minimum water qualities are observed and
oil services are performed in accordance with the manufacturer's instructions.

Technical Circular 0199-99-2105 must be observed for the use of lubricating oils.

Technical Circular 0199-99-02091 is binding for the engine coolant water quality to be used for MWM
engines and quality of water used in heating circuits.

Technical Circular 0199-99-3017 is binding for the released fuel gas qualities to be used for the
operation of MWM engines.

The requirements of Technical Circular 0199-99-2132 must be complied with for the combustion and
intake air.

All Technical Circulars (TR) mentioned in this document have been enclosed.

The operator must document and, where requested by the manufacturer, prove the compliance with the
maintenance, repair and fuel specifications. Where such proof cannot be delivered, this will restrict the
warranty obligation of the manufacturer.

The violation of the guideline "Layout of Power Plants driven by Gas and Diesel Engines" (status 01-
2008) can cause damages or failure of the functions of the gensets or the installation for which MWM
can not accept warranty claims.

Technical Specs – TCG2032V16 2/20

Technical description
Notice: technical data and specification marked with an asterisk (*) are for preliminary information only
and not binding and will be specifically determined upon order placement.

1. Basic scope of supply genset

1.1 Engine TCG 2032 V 16

Modern stationary four-stroke Otto gas engine with lean mixture combustion; V-configuration engine;
water-cooled with exhaust gas mixture turbocharging and intercooling; direction of rotation according to
DIN 6265, counter clockwise (viewed on the flywheel side).

Crankcase
Sphero casting casing with attached cooling water jacket, maintains its rigid shape due to steep side
walls and diagonally screwed bearing blocks; suspended crankshaft; short uncut lubricating oil supply
bores from the hollow camshafts as main oil distributing lines to all lubricating points; lateral drive
chamber apertures with quick-release covers; wet cylinder bushings made of highly wear-resistant
special centrifugal casting; rotation-symmetrical undeformable bushing support; crank chamber
ventilation via oil trap.

Power unit
Crankshaft made of chromium molybdenum steel with screwed-on counterweights and hardened main
and connecting rod bearing necks; full-shaft connecting rods made of steel alloy, forged with inclined
toothed separating level; oil supply of the piston bolt and the piston through the bored connecting rod,
progressive piston pin bearing for reduced piston load, crankpin with guides for the connecting rod;
electron-beam welded light metal piston with asymmetrical crowned compression ring, tapered
compression piston ring and a narrow-land drain oil-control ring, all piston rings with highly wear-
resistant coating; main and connecting rod bearings made of wear- and corrosion-resistant alloys,
sputtered bearing layer; cams made of high-strength steel, bearings and cams hardened, bushings
made of aluminium alloy, drive via gearwheels; flywheel of sphero cast (GGG-50).

Cylinder head
Single cylinder heads made of special cast iron with intermediate bottom and cooling bores in the
combustion chamber plate to reduce mechanical and thermal load; four valves and inserted, hardened
seat rings, outlet seat rings water-cooled; mixture supply from the distributor manifold in the combustion
chamber; exhaust gas discharge to the same side upwards in the combustion chamber; novel unit
comprising cylinder head, bushing and intermediate casing with piston and connecting rod as well as
the intake, exhaust gas, lubricating oil and cooling water line segments for easy assembly and
convenient service; chamber sparkplugs centrically in the combustion spaces with intensive plug seat
cooling.

Valve train
One toothed wheel driven hollow-bored camshaft comprising individual elements for each cylinder bank
on each side of the engine, simultaneously main lubricating oil distribution; valve operation for
respectively 2 inlet and outlet valves by roller tappet, push rod, rocker lever and valve bridge; O ring oil
gaskets at the valve stems.

Technical Specs – TCG2032V16 3/20

Ignition
Microprocessor-controlled high-voltage ignition system with low-voltage distribution; respectively one
ignition coil per cylinder; without moving parts; wear-free; triggered via tooth rim of the flywheel and a
pick-up sensor at the camshaft; variable ignition times; ignition energy and distribution via calculator at
primary side of the ignition coils; high-performance industrial engine or special sparkplugs and
integrated ignition cable; buffered voltage supply by 24 V battery.

Antiknock control
Knock sensor monitoring for each cylinder; ignition control for the individual cylinders, gas-air mixture
and engine power adjustment; knock-free operation at maximum power with best degrees of efficiency
while complying with emission thresholds.

Fuel mixture generation

Air intake via dry air filters (with optical maintenance indicator) into the multigas mixer; gas supply from
safety gas control train; dosing of the gas-air quantity ratio in the multigas mixer.

Fuel mixture charging

Two exhaust gas turbochargers take air and gas out of the gas mixer at atmospheric pressure;
subsequent compression of the gas mixture and re-cooling in the two-stage mixture coolers (low-
temperature stage in the separate cooling circuit); rotary slide valve throttle unit for each cylinder row
downstream of mixture cooler for power control.

Gas mixture control and monitoring

Electronic control and monitoring of the air-gas mixture at the mixer actuator via combustion chamber
temperature (1 temperature sensor per cylinder) and the power/speed, combined in the MWM TEM
system.

Starter
Compressed-air starter turbine with integrated gear and 24 V magnetic valve; pressure reduction station
with ball valve and filter, as well as connection option for compressed-air supply of the engine flywheel
turning device and the electro-pneumatic valves of the gas control train; flanged on crankcase.

Lubricating oil system

Forced-feed circulatory lubrication by toothed wheel pump, lubricating oil cooling in the separate cooling
circuit; oil filter in the main stream; additional fine filter in the auxiliary stream; automatic lubricating oil
refilling into the oil pan through controlled inflow; automatic pre-lubrication by electric pump; oil
discharge by the same pump at the unit; lubricating oil pre-heating by means of separate circulating
pump and plate heat exchanger (heat transfer from cooling water pre-heating).

Cooling water connections

Rubber compensators with counter-flange for connection to the cooling water lines.

Exhaust gas connection

2 pieces stainless steel compensators to be attached with clamps, with the respective welding flanges
for connection to the exhaust gas line.

Technical Specs – TCG2032V16 4/20

Sensors/actuating elements and cabling
Sensors for cooling water temperatures, intake air temperatures, mixture temperatures, oil temperature,
oil level, oil pressure, speed, combustion chamber temperatures, exhaust gas temperatures, exhaust
gas turbocharger speeds, crank chamber pressure, starter air pressure, gas mixer position recording,
knock sensors, actuator throttle element, gas mixer actuators, cooling water pre-heating control, ignition
coils completely cabled to two central connecting elements (respectively 1 connecting element per
cylinder row) by means of detachable connections.

Engine test run

A test run of the engines is performed at the manufacturer's factory. The test runs are performed on
gauged test facilities. The test reports are included in the documents.

Procedure and content of the test:

Test - general
Engine assembly and cabling according to assembly plan
Engine installation on test stand with cold functional test
Engine run-in according to run-in programme

Set engine, leak test and recording of measured values

Engine acceptance
60 min 100% power at rated speed 2 measurements
20 min 50% power 1 measurement
Controller test 100% at zero load

Recording of measured values

Speed, brake force or electrical output, consumption (degree of efficiency), controller position, exhaust
gas temperatures, intake temperature, lubricating oil pressure, lubricating oil temperature, cooling water
pressures high-temperature (HT) and low-temperature circuit (NT), cooling water temperatures NT and
HT, mixture pressure, mixture temperatures downstream of compressor and downstream of mixture
cooler, turbocharger speed, exhaust gas emissions (% O2 dry, mg/m³ i.N. NOx).

Preservation
Standard preservation of the engine to protect against corrosion during transport and possible
subsequent storage at the place of destination. Maximum protection period of 6 months after delivery,
for storage in a closed dry room.

1.2 Three-phase internal pole synchronous generator

Manufacturer: Marelli or Avk

Type: 11000V or 6300V 50 Hz

Design
Generator comprising the main generator as internal pole machine and the exciter generator as external
pole machine. The power supply of the voltage regulator depends on the rated voltage.
The generators are equipped with an auxiliary exciter machine.

Technical Specs – TCG2032V16 5/20

Stator
The stator casing has a welded design. The stator pack is manufactured from hydraulically pressed,
low-loss dynamo sheet and is compressed with the stator by pressure plates into a compact unit. A rigid
design adapted to the special operating conditions prevailing in diesel units is thus achieved.
The stator coil corresponds to insulation class F according to VDE 0530/IEC 34.
The coil heads and switching connections are supported by suitable attachment elements and attached
to each other by fixed mechanic connection and thus protected against dynamic stresses caused by
electrodynamic forces.

Rotor
The rotor comprises the shaft and the main pulse wheel. The main pulse wheel – in salient pole design
– consists of hydraulically pressed sheets or steel plates. By standard, a copper dampening cage is
installed that is electrically connected in the pole shoes and between the poles.
The coils of the main rotor are made of flat copper and are protected by suitable components against
centrifugal forces. The rotor coil corresponds to insulation class F according to VDE 0530/IEC 34. By
standard, the rotor is balanced with half feather key according to VDE 0530/IEC 34, Part 34.

Bearing shields
The bearing shields are welded or made of cast iron. According to the design, the generator feet are
attached underneath the bearings.

Storage
Antifriction bearings are designed as loose bearings on the drive side and as fixed bearings on the
counter-drive side.

Specifications, norms
Design specifications: VDE 0530, IEC 34 (EN 60034), ISO 8528-3

Components/subassemblies/standard design
Terminal box generously dimensioned for installation of current transformers.
Terminal boxes with cable inlet connections and cable strain relief

Electronic control
Basic module MEC 100 D, including failure monitoring:
 highly constant voltage regulation
 reactive-current dependent static
 Underspeed protection by U/F function

Function blocks
 Cos-phi regulator: Cos-phi balancer
o The power factor of the controlled generator is the same as that of the entire current or of
the current of the other generators (depending on the current transformer connection)
o Suitable for parallel operation with generators without linear voltage static
o Generators protected by adjustable over- and under-excitation limits
o Target value setting by potentiometer or by current signal 4 20 mA

Technical Specs – TCG2032V16 6/20

  Voltage balancer: Automatic synchronisation balancer
o Automatic adaptation of the generator idle voltage to the mains voltage prior to
synchronising
o No separate voltage adjustment by additional devices in the switchgear required

 Exciter and diode monitoring: Exciter system monitoring – direct current relay; delivery loose for
installation in the control/switch panel
o Recording of over- and under-excitation states
o Recording of faults of the rotating diodes by means of unevenness of the direct current of
the exciter

 Static transformer: for parallel operation with the mains and with each other, installed in the
generator

 Auxiliary heating: installed in the generator

 Temperature monitoring
o 6 PT 100 sensor for coil
o 1 PT 100 sensor for each bearing

Electrical data and properties

Voltage operating range
Voltage adjustment range
Voltage accuracy, static
Uninterrupted short-circuit current
Overload capability
or
Overspeed
Between 90 ... 110 % of the rated voltage
+10 % / -10 % rated voltage for continuous operation
 0.5 ... 1 %
For 3-pole terminal short-circuit at least 3 x rated current for 3 s
10 % for 1 h, within 6 h
according to IEC 34/VDE 0530, i.e. 50 % for 30 s.
according to VDE 0530 for 1.2 the rated speed for 2 min

1.3 Genset components

Base frame
Bending and torsion resistant steel construction for supporting the engine and the generator. Elastic
bearing elements are mounted underneath the support frame.

Coupling
Highly elastic, axial plug-type flange coupling for torsion-elastic connection of motor and generator. The
disk-shaped rubber body dampens torsional vibrations to a high degree. The rubber element is radially
dismountable.

Pre-lubrication pump
Pre-lubrication by electric pump at the plant; depletion option with the same pump after changing the
attached three-way valve.

Technical Specs – TCG2032V16 7/20

Additional parts of the plant
The components listed in the following are delivered "loose" and are not mounted to the plant. The
assembly must be carried out on site by the customer.
1 set of maintenance-free steel feather elements with height adjustment for easy adjustment of the unit
on the foundation at the customer's. A vibration insulation of approx. 88 – 94 % can be achieved with
these bearing elements. Structure-borne noise is reduced by a rubber fibre plate on the bottom side of
the bearing.
 2 pieces magnetic valves with connecting parts for lubricating oil flow
 1 piece fan for ventilating the crankcase with integrated filtering of the oil mist vapours for
discharging the exhaust air
 1 piece differential pressure monitor for monitoring the crank chamber ventilation fan
 1 can touch-up paint RAL 5010

1.3.1 Air pre-heating and filtering unit for floor mounting

The function of the combustion air pre-heating is to provide a constant combustion air temperature in
the intake system of the engine. The following components are included in the delivery scope and are
delivered "loose".

 unit comprising two casings (one casing for each cylinder row) in that an air-water-heat exchanger and
respectively 4 filter cartridges slabs are mounted. The filter slabs are to be equipped with quick-release
fasteners for quick and easy tool-less replacement. The casing contains a maintenance indicator that
indicates low pressure for easy monitoring of soiling of the filter cartridge
 2 pieces resistant special hoses for connection between gas mixer and air pre-heating unit + hoses
clamps
 1 piece three-way valve DN 32 + counter flanges for controlling the air-temperature quantity in the air-
water-heat exchanger
 2 pieces valve flaps DN 40 + counter flanges
 2 pieces throttle valves + counter flanges
 1 piece floating air valve
 1 piece water pump + counter flanges

1.4 Genset assembly

Assembly
Gas engine and generator are coupled elastically, mounted on the common support frame, for vibration-
insulated installation using feather elements on appropriate foundation at the customer's.

Paint
Resistant paint coating comprising:
 Wash primer coating for non coated components made of stainless steel, non-ferrous metals,
galvanised and chromated parts, dry coat thickness 10+5 µm
 Priming coat for complete unit, dry coat thickness 40+30 µm
 Top coat in colour RAL 5010 for complete unit, dry coat thickness 90+40 µm

Cabling
Complete cabling of the plant to terminal strips and terminal box

Technical Specs – TCG2032V16 8/20

1.5 Zero-pressure gas control train with connecting accessories

Zero-pressure gas control train

Loose delivery, the assembly must be carried out by the customer.

Gas type 1: natural gas

Nominal diameter: DN125/100/125

Safety gas control train according to DVGW as compact unit.

Operating side on the right in direction of gas flow, comprising:

 1 piece ball valve

 1 piece gas filter
 1 piece manometer
 1 piece pressure monitor
 2 pieces pneumatic valves
 1 piece zero-pressure governor
 1 piece outlet adaptor
 2 pieces counter flanges for assembly of the gas control train in the gas line

The gas control train is designed for a gas flow pressure of 300 mbar with a permissible variation of ±
10%, variation frequency < 1/6 min.
The equipment of the gas control train might vary, depending on the type of gas or operation. The
separate parts list as listed upon placement of the order is binding.

1.6 TEM-EVO system

Loose delivery, assembly and cabling to be carried out by the customer.

The MWM Total Electronic Management (TEM) system combines the control and monitoring of all
functions of a gas engine, as well as of the auxiliary engine drives in one unit. Its monitoring functions
protect the engine against impermissible limiting states, guaranteeing high runtimes. The TEM-EVO
system controls and optimises gas combustion in the cylinders. Integrated control functions ensure
optimised and reproducible engine values in all operating states. Thanks to a wide range of options, it is
possible to adjust the TEM-EVO system optimally for specific applications.
Apart from the TEM-EVO system, only contactors, synchronising unit, generator/mains protection and
effective power measurement must be made provision for in the control cabinet of the auxiliary power
unit.

Setup

Technical Specs – TCG2032V16 9/20

The TEM-EVO system comprises 3 components:

Power unit control cabinet ("AGS")

Complete with connected cables to the unit; contains the unit control and the TÜV certified safety chain.

I/O controller
For installation in the control cabinet of the auxiliary power unit.

Workstation

The system can flexibly be adjusted to the local conditions. Susceptibility to failure and cabling
expenditure for the plant is minimised.
The unit control cabinet is installed in direct vicinity to the unit. The engine cables are tested at the
factory and the cables are tested and fully connected to the unit control cabinet to ensure trouble free
commissioning and high operational reliability.
The signals that are relevant to the power stack are exchanged directly with the TEM-EVO system via
the I/O controller in the auxiliary power unit control cabinet. Data are transmitted to the unit control via a
highly fault free CAN bus connection.
The workstation can be placed anywhere on the plant, at the unit or in the switch room, at the
customer's choice.

Technical Specs – TCG2032V16 10/20

Basic functions
 Automatic program sequence for start and stop for the gas engine plant
 Reliable control of the exhaust gas emissions to low values
 Integrated digital speed and power control
 TÜV certified safety chain
 Connection of actuators and sensors at the I/O controller in the auxiliary power unit control
cabinet and data transmission via CAN bus to the TEM-EVO unit cabinet
 Monitoring of all sensors at the unit
 Monitoring of the engine cooling water
 Control and monitoring of the lubricating oil circuit inclusive oil pre- and after-lubrication as well
as oil change
 Test mode for checking the connected actuators, sensors and auxiliary power units
 Electronic line recorder for measured values for control and diagnostic purposes over periods of
40h/6min as well as synchronous with work cycle
 Electronic operation diary for recording any warning, malfunction and operational messages with
date and time for detailed monitoring of the operation
 Electronic operating hours counter with breakdown in 5 load ranges
 Connection option for one workstation
 [MK] Engine cooling water control: The cooling water circuit control ensures an optimal cooling
water temperature by piloting a three-way valve. The cooling water inflow temperature is
increased for partial load
 [GK] Intercooling circuit: Control of the intercooling water inflow temperature by piloting a control
valve in the intercooling water circuit; monitoring of the receiver temperature
 [IOC] I/O controller: The I/O controller controls the auxiliary power units, pumps, valves, etc. and
records the respective measured values The I/O controller is delivered loose for installation in
the auxiliary power unit control cabinet
 [16M] 16 configurable messages: Digital inputs with comprehensive configuration options in
order to be able to connect plant-specific malfunctions, warnings or messages directly to the
TEM-EVO system. Monitoring a plant is thus considerably easier and clearer by the protocol
function in the operation diary. For such purpose, the configurable messages are arranged as
potential-free contacts (openers) in the TEM auxiliary power unit control cabinet at the I/O
controller
 [SER] Serial coupling for data exchange: Exchange of data, such as e.g. target values,
measured values, messages, warnings and malfunctions, with super ordinate control via serial
coupling using protocol 3964R with RK512 via TTY or CS 20 mA.
 [AKRK] Antiknock control: Highly dynamic individual antiknock control for each cylinder to ensure
safe operation of the engine also at a low methane number. Maximum possible power with best
degrees of efficiency while complying with emission thresholds
 [GL] Monitoring of the generator bearing temperatures: Display (screen, history, serial coupling)
and monitoring of the two generator bearing temperatures. A malfunction or warning is triggered
if a configurable limit value is exceeded

Technical Specs – TCG2032V16 11/20

  [GLT] To protect the engine, the basic bearing temperature (main engine bearing temperature) is
recorded and monitored in the TEM-EVO. Exceeding the limit value will trigger a warning and
then a malfunction, depending on by how much it was exceeded
 [SATL2] Measurement and restriction of the exhaust gas turbocharger speeds: Display (screen,
history, serial coupling) and restriction of the exhaust gas turbocharger speeds
 [NATL2] Variable monitoring of the exhaust gas temperature after exhaust gas turbochargers A
and B: Display (screen, history, serial coupling) and variable monitoring of the exhaust gas
temperature after the exhaust gas turbocharger. A malfunction will be triggered if a configurable
limit value is exceeded
 [BSX], [BSXK] Preliminary setup for eService system [BSX] with cable loom [BSXK]: Preliminary
setup for remote operation of the TEM EVO (BSX): required for each TEM EVO that is to be
connected to an eService modem system, a mechanical change-over switch or an intelligent
selection unit (IAE)
 [AVW] The TEM-EVO controls the intake air pre-heating by piloting the control valve. Where
preheating is requested, the intake air temperature is regulated according to the configurable
target value. The controller actuates the control valve of the heat exchanger unit
 [VAWT/VSWT]Measurement of the heating water temperature upstream of the exhaust gas heat
exchanger and before lubricating oil heat exchanger
 [SPC] Connection for service PC: Rugged service connector at the TEM-EVO unit control
cabinet. When the service PC is connected, a control unit will interrupt the connection to the
workstation or any modem that might be connected. The TEM-EVO system can then be
operated from the service PC
 [2xNKAT] To protect the catalytic converter, the TEM-EVO measures the exhaust gas
temperature after the catalytic converter and monitors it in dependence on the operating point. A
malfunction will be triggered if the configurable limit value is exceeded

Operation
An intelligent workstation provides access to all functions ensuring easy operation of the TEM EVO
system The workstation is equipped with a 15" TFT touch monitor. The touch function of the workstation
ensures easy and intuitive operation of the unit. Using the navigation bar, the user can operate the unit
by quick and direct changing between screens. Each workstation screen provides the user with
information on the state of the connected unit. All regulation, service, control and monitoring functions
can conveniently be operated without the need for long training.
Communication with the user can be in one of many available national languages of the TEM EVO
system. The language can quickly be changed at any time by pressing a button. In the event of a
service, a different language than the one used by the plant staff may temporarily be set. All information
that is important for normal operation and operating options are clearly summarised on the "Operation"
screen (Fig. 1) (the figure below also contains options).

Technical Specs – TCG2032V16 12/20

Figure 1: The most important information and operating options at a glance

Operation diary
With its recording function, the electronic operation diary (Fig. 2) of the TEM-EVO system makes the
operation of the gas engine plant and its peripheral devices transparent. All operation messages and
switching actions that are important for the operation as well as any changes to the configuration are
recorded with the exact time stamp (date/time). In total, the TEM-EVO system can monitor and
distinguish more than 600 different incidents. This allows for quick and detailed analysis of the operation
of the unit incl. the auxiliary functions controlled by the TEM EVO.

Technical Specs – TCG2032V16 13/20

Figure 2: Recording functions of the operation diary

The curves can be followed with the cursor; the respective measured value is depicted as numeric value
with exact time stamp. In the event of a failure, the recording will stop automatically after 40s to facilitate
failure diagnosis. The "Real-time scope" function allows for continuous monitoring of measured values
and control function.
These measured values can optionally be saved for further analysis and re-read at a later time.

Technical Specs – TCG2032V16 14/20

1.7 Commissioning spare parts

Commissioning spare parts comprising:

 1 set of parts as spares for commissioning

1.8 Standard documentation

The delivery of each plant includes 2 copies of the documentation in English. Comprising:
 Gas engine operating instructions
 Gas engine spare parts list
 Gas engine test stand protocol
 Exhaust gas turbocharger operating instructions
 TEM system operating instructions
 System manual for data exchange via serial interface
 Generator operating instructions
 Generator drawing and generator shaft drawing
 Generator circuit diagrams
 Generator test stand protocol
 Coupling operating instructions
 Elastic bearing assembly notes
 Assembly notes for rubber compensators for engine connections cooling water/oil
 Assembly notes for compensator engine connection exhaust
 Circuit diagram for unit cabling
 Circuit diagram for plant cabling (for MWM delivery scope)
 Circuit diagram for TEM system
 Gas control train operating instructions
 Gas control train test certificate
 Gas control train drawing
 Drawing and technical data of the magnetic valves for lubricating oil line
 Drawing and technical data of the pre-lubrication pump
 Technical description of the plant components delivered by MWM
 RI flow diagram
 Unit drawing
 Plant diagram (option)
 Foundation load calculation sheet
 Manufacturer's Declaration

Technical Specs – TCG2032V16 15/20

1.9 Tools

Set standard tools 1

Comprising:
 Tool set
o Toolbox
o Double open ended wrench DIN 003110- 8×10
o Double open ended wrench DIN 003110-12×14
o Double open ended wrench DIN 003110-14×15
o Double open ended wrench DIN 003110-13×17
o Double open ended wrench DIN 003110-19×22
o Double open ended wrench DIN 003110-24x27
o Double open ended wrench DIN 003110- 30×32
o Double ended ring spanner DIN 000838-13×17
o Double ended ring spanner DIN 000838-19×22
o Double ended ring spanner DIN 000838-24x27
o Feeler gauge set DIN 002275-D
o Socket wrench insert DIN 003124- 10×12.5
o Hinged handle
o Socket wrench insert DIN 003124-13×12.5
o Socket wrench insert DIN 003124- 14×12.5

Sparkplug wrench for mounting and dismounting sparkplugs

Comprising:
 Socket wrench
 Grooved nut key

Compressed-air operated drive for turning the engine flywheel during maintenance and repair
Comprising:
 Compressed air motor
 Operating device

2. System components

The following components are included in the delivery scope and are delivered as a "loose" item.

2.1 Heat utilisation

Note regarding the following descriptions:
The figures in the { } brackets refer to the numbering of the electric transducers as used in the P&ID
flowchart and the respective terminal plan for the unit and the TEM system.
The technical data includes design values which may differ from the values specified in the genset data
sheets.

Technical Specs – TCG2032V16 16/20

2.2.1 Intercooling system (GK)

In the intercooling system, the heat that was generated during compression of the fuel gas mixture in
the exhaust gas turbocharger is extracted in a specially designed heat exchanger.

Cooling water monitoring group (GK)

Premounted monitoring group in a stable and painted steel casing with flange connection (delivery
scope does not include counter flanges and gaskets) for direct installation in the pipework of the plant,
comprising:
Casing
Connection flanges 80 / 10 DN/PN
Paint 3000 RAL

Floating air valve in hot-pressed brass design with red brass effect, with caulked shut-off device and
corresponding shut-off valve.
Maximum temperature 120 °C
Maximum pressure 10 bar
Connection size 1/2 G
Water level limiter with glass floater as glandless device with magnetic transmission of the floater
movement to a micro switch.
Protection type 65 IP
Micro switch Single-pole change-over contact
Max. operating overpressure 10 bar
Max. operating temperature 120 °C
Installed position Main axle vertical
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary
handle.
Casing made of hot-pressed brass/red brass, spring cap made of GD Zn/hot-pressed brass/MS cast,
inner parts made of Ms 58, membrane and gasket made of high-temperature resistant non-ageing
rubber elastic plastic, spring made of corrosion-resistant spring steel wire
Response overpressure 3 bar
Operating temperature max. 140 °C

Three-way valve (GK)

Three-way valve with actuator, designed as pressurising valve.

Control valve
maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle
made of 1.4571, tight-closing.
Connections* 80 / 16 DN / PN

Technical Specs – TCG2032V16 17/20

Actuating drive
electric actuator drive, 5 kN, permissible ambient temperature -20°C to +70°C, protection type IP 65,
mechanical stroke indicator, manual override.
Motor voltage/frequency 230 / 50 / 60 V/Hz
Capacity 26 VA
1" R
80 / 16 DN / PN

Differential pressure monitor for flow control (GK) {PDSA- 309}

Differential pressure measuring and switching unit with robust movement and attenuator valve,
measuring elements made of surface-treated steel 1.4310, with micro switch (single-pole change-over
contact).
Measurement range 0 to 0.6 bar
Max. static operating pressure 10 bar
Permissible ambient temperature -10 to 70 °C
Permissible medium temperature 70 °C
Protection type 54 IP
 Pressure connection (olive type fitting) 12 mm
Differential pressure switch value (preset) 80 mbar

2.3.2 Engine cooling water system (MK)

The heat from the cylinder cooling that is generated during operation of the gas engine is dissipated via
the engine cooling water circuit.
The respective lubricating oil heat is also dissipated in the engine cooling water circuit by transfer
through a plate heat exchanger.

Lubricating oil heat exchanger (MK)

Lubricating oil/cooling water plate heat exchanger; designed according to AD memos/pressure
equipment directive.

Lubricating oil Cooling water

Thermal rating kW 510
Temperature (inlet/outlet)* °C 88 / 80 75 / 79
Volume flow* m³/h 125 121
Pressure loss* bar 1 0,66
Connections* DN / PN 100 / 16 100 / 16
Length × width × height* mm 1655 × 580 × 1579
Content* litres 125 121
Max. temperature* °C 120
Max. operating pressure* bar 16
400 V

Technical Specs – TCG2032V16 18/20

Cooling water monitoring group (MK)
Premounted monitoring group in a stable painted steel casing with flange connection (delivery scope
does not include counter flanges and gaskets) for direct installation in the pipework of the plant,
comprising:
Casing
Connection flanges 100 / 10 DN/PN
Paint 3000 RAL
Floating air valve in hot-pressed brass design with red brass effect, with caulked shut-off device and
corresponding shut-off valve.
Maximum temperature 120 °C
Maximum pressure 10 bar
Connection size ½ G

Water level limiter with glass floater as glandless device with magnetic transmission of the floater
movement to a micro switch.
Protection type 65 IP
Micro switch Single-pole change-over contact
Max. operating overpressure 10 bar
Max. operating temperature 120 °C
Installed position Main axle vertical
Membrane safety valve with upstream seat gasket separate from the membrane, liftable by rotary
handle, casing made of hot-pressed brass/red brass, membrane and gasket made of high-temperature
resistant non-ageing rubber elastic plastic.
Response overpressure 3 bar
Operating temperature max. 140 °C

Three-way control valve (MK)

Three-way valve with actuator, designed as pressurising valve.

Control valve
maintenance-free soft-sealing heating control valve, casing made of GG-25, 3-way valve shape, spindle
made of 1.4571, tight-closing.
Connections* 125 / 16 DN / PN

Actuating drive
electric actuator drive, 5 kN, permissible ambient temperature -20°C to +70°C, protection type IP 65,
mechanical stroke indicator, manual override.
Motor voltage/frequency 230 / 50 / 60 V/Hz
Capacity 53 VA
1" R

Technical Specs – TCG2032V16 19/20

Differential pressure monitor for flow control (MK) {PDSA- 126}
Differential pressure measuring and switching unit with robust movement and attenuator valve,
aluminium pressure chamber, measuring elements made of surface-treated steel 1.4310, with micro
switch (single-pole change-over contact).
Measurement range 0 to 0.6 bar
Max. static operating pressure 10 bar
Permissible ambient temperature -10 to 70 °C
Permissible medium temperature 70 °C
Protection type 54 IP
 Pressure connection (olive type fitting) 12 mm
Differential pressure switch value (preset) 80 mbar

3. Services

3.1 Packing
Standard foil packing for truck land transport.

Technical Specs – TCG2032V16 20/20