GAS GENERATOR SET

NATURAL GAS CONTINUOUS

(For CHP Applications) 2000 ekW 2500 kVA 50 Hz 1500 rpm
Caterpillar is leading the power generation marketplace with power solutions engineered to deliver unmatched flexibility, expandability, reliability and cost-effectiveness.
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FEATURES
EMISSIONS Meets most worldwide emission levels down to 0.5 g/bhp-hr (250 mg/Nm3) Nox level without after treatment FULL RANGE OF ATTACHMENT Wide range of bolt-on system expansion attachments, factory designed and tested. Flexible packaging options for easy and cost effective installation. PROVEN SYSTEM Fully prototype tested. Field proven in a wide range of applications worldwide. Certified torsional vibration analysis available WORLDWIDE PRODUCT SUPPORT Cat G3520C GAS ENGINE Robust high speed diesel block design provides prolonged life and lower owning and operating costs Designed for maximum performance on low pressure gaseous fuel supply. Simple open chamber combustion system for reliability and fuel flexibility. Leading edge technology in ignition system and air/fuel ratio control for lower emission and engine efficiency One electronic control module handles all engine functions: ignition, governing, air/fuel ratio control and engine protection CAT SR4B GENERATOR Designed to match performance and output characteristics of Cat gas engines Industry leading mechanical and electrical design

Cat dealers provide extensive post sales High efficiency support including maintenance and repair agreements CAT EMCP II+ CONTROL PANEL Cat dealers have over 1,800 dealer branch Simple user friendly interface and navigation stores operating in 200 countries Digital monitoring, metering and protection setting The Caterpillar SOS SM program cost Fully-featured power metering and protection relayin effectively detects internal engine component UL508A Listed conditions, even the presence of unwanted Remote control and monitor capability options fluids and combustion by-products

LEHE2833-02

CONTINUOUS 2000 ekW 2500

50 Hz 1500 RPM

FACTORY INSTALLED STANDARD & OPTIONAL EQUIPMENT

System Gas Engine Control Module (GECM) Standard
Fuel/air ratio control; Start/stop logic: gas purge cycle, staged shutdown; Engine Protection System: detonation sensitive timing, high exhaust temperature shutdown; Governor: Transient richening and turbo bypass control; Ignition. Island Mode Feature -- addiitonal engine control module , new software and engine sensors

Optional

Air Inlet Control Panel

Two element, single-stage air cleaner with enclosure and service indicator

Air cleaner with precleaner; Mounting stand EMCP II+ Local alarm module; Remote annunciator; Communications Module (PL1000T, PL1000E) Synchronizing module; Engine failure relay

Cooling Exhaust

ANSI/DN customer flange connections for JW inlet and outlet Cat flanges on SCAC circuit Dry exhaust manifolds, insulated and shielded; Center section cooled turbocharger with Cat flanged outlet; Individual exhaust port and turbocharger outlet wired to Integrated Temperature Sensing Module (ITSM) with GECM providing alarms and shutdowns.

Coolant level drain line with valves, fan with guard; Inlet/Outlet connections. Flange; Exhaust expander; Elbow; Flexible fitting; Muffler and spark-arresting muffler with companion flanges.

Fuel

Electronic fuel metering valve; Throttle plate, 24V DC actuator, controlled by GECM; 3 Fuel system is sized for 31.5 to 47.2 MJ/Nm (800 to 1200 Btu/cu ft) dry pipeline natural gas with pressure of 10.2 to 34.5 kPa (1.5 to 5 psi) to the engine fuel control valve.

Fuel filter; Gas pressure regulator; Gas shutoff valve, 24V, ETR (Energized-To-Run)

Generator

SR4B generator, includes: Cat Digital Voltage Regulator (Cat DVR) with 3-phase sensing and KVAR/PF control; Reactive droop; Bus bar connections; Winding temperature detectors; Anti-condensation space heater.

Medium and high voltage generators and attachments; Low voltage extension box; Cable access box; Air filter for generator; Bearing temperature detectors; Manual voltage control; European bus bar. Woodward load sharing module

Governing

Electronic speed governor as part of GECM; Electronically-controlled 24V DC actuator connected to throttle shaft.

Ignition Lubrication Mounting Starting / Charging

Electronic Ignition System controlled by GECM; Individual cylinder Detonation Sensitive Timing (DST) Lubricating oil; Gear type lube oil pump; Oil filter, filler and dipstick; Integral lube oil cooler; Oil drain valve; Crankcase breather. 330 mm structural steel base (for low and medium voltage units); Spring-type anti-vibration mounts (shipped loose) 24V starting motors; Battery with cables and rack (shipped loose); Battery disconnect switch; 60A, 24V charging alternator (standard on 60Hz 1800rpm only) Charging alternator; Battery charger; Oversized battery; Jacket water heater; Crankcase explosion relief valve; Engine barring group; EEC D.O.I and other certifications Oil level regualtor; Prelube pump; Positive crankcase ventilation system

General

Paint -- Caterpillar Yellow except rails & radiators; Damper guard. Operation and Maintenance Manuals; Parts Book.

LEHE2833-02

CONTINUOUS 2000 ekW 2500 kVA

50 Hz 1500 RPM

SPECIFICATIONS
GAS ENGINE CAT EMCPII+ CONTROL PANEL G3520C SCAC 4-stroke-cycle, watercooled gas engine Power by 24 volts DC Number of Cylinders V20 NEMA 12, IP44 dust-proof enclosure Bore --- mm (in) 170 (6.7) Lockable hinged door Stroke --- mm (in) 190 (7.5) Single-location customer connection Displacement --- L (cu in) 86.3 (5266) Auto start/stop control switch Compression Ratio 11.3:1 Voltage adjustment potentiomenter Aspiration Turbocharged Separate Circuit Aftercooled True RMS AC metering, 3 phase Cooling Type Two stage aftercooler, JW + O/C + A/C 1 Combined Purge cycle and staged shutdown logic Fuel System Low Pressure Digital indication for: Governor Type Electronic (ADEM III) RPM Operating hours Oil pressure Coolant temperature Consult your Cat dealer for all available voltages and performance DC voltage L-L volts, L-N volts, phase amps, Hz, ekW, kVA, kVAR, kWhr, %kW, pf System diagnostic codes Shutdown with indicating lights; Low oil pressure High coolant temperature High oil temperature Overspeed Overcrank Emergency stop Detonation sensitive timing Programmable protective relaying functions: Under / Over voltage Under / Over frequency Overcurrent Reverse power Spare indicator LEDs Spare alarm/shutdown inputs

LEHE2833-02

CONTINUOUS 2000 ekW 2500 kVA

50 Hz 1500 RPM

TECHNICAL DATA
G3520C Gas Generator Set Emission level (NOx) Aftercooler SCAC (Stage 2) Package Performance (1) Power Rating @ 0.8 pf (without water pumps and without fan) Power Rating @ 0.8 pf (without water pumps and without fan) Power Rating @ 1.0 pf (without water pumps and without fan) (2) Electric Efficiency @ 1.0 pf (ISO 3046/1) Mechanical Power (without water pumps and without fan) Fuel Consumption (3) 100% load w/o fan 75% load w/o fan 50% load w/o fan Altitude Capability (4) At 25 C (77 F) ambient, above sea level Cooling System Ambient air temperature Jacket water temperature ( Maximum outlet ) Exhaust System Combustion air inlet flow rate Exhaust stack gas temperature Exhaust gas flow rate Exhaust flange size ( internal diameter ) Heat Rejection (5) Heat rejection to JW, oil cooler and AC - Stage 1 Heat rejection to AC - Stage 2 Heat rejection to exhaust (LHV to 25 C) Heat rejection to exhaust (LHV to 120 C) Heat rejection to atmosphere from engine Heat rejection to atmosphere from generator (Typical) Lubrication System Standard sump refill with filter change (7) Emissions NOx @ 5% O2 (dry) CO @ 5% O2 (dry) THC @ 5% O2 (dry) NMHC @ 5% O2 (dry) Exhaust O2 (dry) mg/Nm Deg C ekW Continuous kVA Continuous ekW Continuous % bkW
3

DM 5844 DM 5847 500 32 2000 2500 2020 40.5 2070 350 32 2000 2500 2020 39.8 2070

DM5849 250 32 2000 2500 2020 39.4 2070

DM5838 500 54 2000 2500 2020 40.5 2070

DM5840 350 54 2000 2500 2020 39.9 2070

DM5842 250 54 2000 2500 2020 39.6 2070

Nm /hr 3 Nm /hr 3 Nm /hr m Deg C Deg C Nm /min Deg C 3 Nm /min mm kW kW kW kW kW kW L mg/Nm mg/Nm mg/Nm mg/Nm %
3 3 3 3 3

505 389 271 390 25 90 145 449 154 328 1040 197 1679 1190 125 64 541 500 971 2675 402 9.3

513 396 276 298 25 90 149 449 154 328 1050 200 1750 1239 125 64 541 350 962 2899 435 9.6

518 400 279 238 25 90 151 457 160 328 1055 202 1797 1270 125 64 541 250 957 3048 458 9.7

504 387 269 250 25 90 147 453 156 328 1074 126 1712 1219 125 64 541 500 1043 2643 397 9.4

512 393 273 250 25 90 150 456 159 328 1094 131 1762 1254 125 64 541 350 998 2768 416 9.5

516 396 276 250 25 90 152 458 161 328 1108 134 1793 1274 125 64 541 250 968 2851 428 9.5

LEHE2833-02

CONTINUOUS 2000 ekW 2500 kVA

50 Hz 1500 RPM

TECHNICAL DATA
G3520C Gas Generator Set Emission level (NOx) Aftercooler SCAC (Stage 2) Package Performance (1) Power Rating @ 0.8 pf (without water pumps and without fan) Power Rating @ 0.8 pf (without water pumps and without fan) Power Rating @ 1.0 pf (without water pumps and without fan) Electric Efficiency @ 1.0 pf (ISO 3046/1) (2) Mechanical Power (without water pumps and without fan) Fuel Consumption (3) 100% load w/o fan 75% load w/o fan 50% load w/o fan Altitude Capability (4) At 25 C (77 F) ambient, above sea level Cooling System Ambient air temperature Jacket water temperature ( Maximum outlet ) Exhaust System Combustion air inlet flow rate Exhaust stack gas temperature Exhaust gas flow rate Exhaust flange size ( internal diameter ) Heat Rejection (5) Heat rejection to JW, oil cooler and AC - Stage 1 Heat rejection to AC - Stage 2 Heat rejection to exhaust (LHV to 25 C) Heat rejection to exhaust (LHV to 120 C) Heat rejection to atmosphere from engine Heat rejection to atmosphere from generator (Typical) Lubrication System Standard sump refill with filter change Emissions (7) NOx @ 5% O2 (dry) CO @ 5% O2 (dry) THC @ 5% O2 (dry) NMHC @ 5% O2 (dry) Exhaust O2 (dry) mg/Nm Deg C ekW Continuous kVA Continuous ekW Continuous % bkW
3

DM 5845 500 32 2000 2500 2020 40.6 2070

DM 5848 350 32 2000 2500 2020 39.9 2070

DM5850 250 32 2000 2500 2020 39.5 2070

DM5839 500 54 2000 2500 2020 40.5 2070

DM5841 350 54 2000 2500 2020 39.9 2070

DM5843 250 54 2000 2500 2020 39.6 2070

Nm /hr 3 Nm /hr 3 Nm /hr m Deg C Deg C Nm /min Deg C 3 Nm /min mm kW kW kW kW kW kW L mg/Nm mg/Nm mg/Nm mg/Nm %
3 3 3 3 3

504 389 271 390 25 99 146 450 155 328 985 227 1684 1198 138 64 541 500 981 2633 395 9.4

512 395 275 298 25 99 149 456 158 328 994 230 1756 1247 138 64 541 350 973 2855 429 9.7

518 400 278 238 25 99 152 459 161 328 999 232 1802 1279 138 64 541 250 968 3002 451 9.8

504 387 269 350 25 99 147 446 155 328 1011 155 1733 1257 138 64 541 500 1035 2381 358 9.2

512 393 273 350 25 99 149 468 158 328 1030 160 1784 1293 138 64 541 350 990 2493 374 9.3

516 396 276 350 25 99 156 469 160 328 1042 184 1815 1314 138 64 541 250 960 2567 386 9.4

LEHE2833-02

CONTINUOUS 2000 ekW 2500 kVA

50 Hz 1500 RPM

RATING DEFINITIONS AND CONDITIONS

(1) Continuous --- Maximum output available for an unlimited time Ratings are based on pipeline natural gas having a Low Heat Value (LHV) of 35.6 MJ/Nm (905 Btu/ft ) and 80 Cat Methane Number. For values in excess of altitude, ambient temperature, inlet/exhaust restriction, or different from the conditions listed, contact your local Cat dealer. (2) Efficiency of standard generator is used. For higher efficiency generators, contact your local Cat dealer. (3) Ratings and fuel consumption are based on ISO3046/1 standard reference conditions of 25 C (77 F) of ambient temperature and 100 kPa (29.61 in Hg) of total barometic pressure, 30% relative humidity with 0, +5% fuel tolerance. (4) Altitude capability is based on 2.5 kPa air filter and 5.0 kPa exhaust stack restrictions. (5) Heat Rejection --- Values based on nominal data with fuel tolerence of +/-2.5% and 2.5 kPa inlet and 5.0 kPa exhaust restrictions. (6) Assume synchronous driver (7) Emissions data measurements are consistent with those described in EPA CFR 40 Part 89 Subpart D & E and ISO8178-1 for measuring HC, CO, PM, NOx. Data shown is based on steady state engine operating conditions of 25 C (77 F), 96.28 kPa (28.43 in Hg) and fuel having a LHV of 35.6 MJ/Nm3 (905 Btu/cu ft) and 80 Cat Methane Number at 101.60 kPa (30.00 in Hg) absolute and 0 C (32 F). Emission darta shown is subject to instrumentation, measurement, facility, and engine fuel system adjustment.
3 3

LEHE2833-02

CONTINUOUS 2000 ekW 2500 kVA

50 Hz 1500 RPM

DIMENSIONS

Package Dimensions Length Width Height Approx. Shipping Weight 6259.9 mm 1827.5 mm 2254.0 mm 18,350 kg 246.42 in 71.95 in 88.74 in 40,455 lb

Note: Weights and dimension are representative of a 400 Volt genset. Do not use for installation design. See general dimension drawings for details (Drawing: # 234-3560)

Performance Numbers: DM5838, DM5839 DM5840, DM5841 DM5842, DM5843 DM5844, DM5845 DM5847, DM5848 DM5849, DM5850 Feature Codes: 520GE24, 520GE25 520GE26, 520GE27 520GE47, 520GE48 520GE49, 520GE50

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Source: US Sourced LEHE2833-02 LEHE2833-02 (05-11)

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