A TOGNUM GROUP BRAND

GAS GENERATOR SET

FROM NATURAL GAS
YOUR REQUIREMENT
IS OUR ASSIGNMENT:
BETTER ENERGY
FOR A BETTER FUTURE.
MTU Onsite Energy is one of the core brands of Tognum
AG, a world-leading provider of distributed energy
systems, diesel engines, fuel injection systems and
complete propulsion systems for ships, heavy-duty land
and rail vehicles, military vehicles and the oil and gas
industry.
Under the umbrella of Tognum AG, MTU Onsite Energy
bundles the competencies for distributed energy systems
and offers you comprehensive, intelligent and innovative
system solutions for diesel and gas technology – for all
applications, for the most diverse needs.
Sustainability is one of MTU Onsite Energy’s core values.
Today and in the future, our focus is on developing and
implementing system solutions for producing energy from
climate-neutral, regenerative fuels– such as combined
heat and power plants (CHP) fueled by natural gas. The
CHP systems of MTU Onsite Energy not only supply
energy – they provide “better energy”.
Better energy
In the future, natural gas will replace other fossil fuels to
produce clean energy and to improve the global ecological
balance. Natural gas fueled energy modules and generator
sets from MTU Onsite Energy are technologically
advanced solutions with outputs ranging from 100 kWel
to 2.2 MWel that combine environmental sustainability
with economic efficiency.

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COMBINING OUR ENERGIES
TO MAKE ENERGY:
ECONOMICAL, RELIABLE,
SUSTAINABLE.
MTU benefits from more than 100 years of experience in
manufacturing engines. MTU Onsite Energy can rely on
more than 35 years of expertise in development, design,
manufacturing and support of complete systems. All
distributed gas power systems we design and realize
benefit from this outstanding combination of know-how.
The use of biogas and sewage gas is one of the typical
applications for MTU Onsite Energy CHP generators and
modules based on gas engines.
Whether for power generation alone, for cogeneration
(CHP) or trigeneration (CHPC), whether for farmers,
municipal authorities or the commercial sector: We
develop systems solutions specifically configured
for individual applications and customer requirements.
4 / // / MTU Onsite Energy
Our technology offers many advantages:
// Economical
Depending on the conditions, the use of these systems
offers promising revenue potential. Size and number of
modules are defi ned by a profitability analysis for each
specific application. The analysis also demonstrates the
customer’s profit potential when using an MTU Onsite
Energy CHP system.
// Environmentally friendly
In accordance with energy policies, MTU Onsite Energy
focuses on reducing the emissions of greenhouse
gases. In comparison with conventional power
generation, MTU Onsite Energy CHP modules provide a
CO2 reduction of up to 50 %.
// Sustainable
Combined heat and power (CHP) systems use a // Independent
combustion engine to drive a power generator. Heat An onsite distributed heat and energy supply saves
accrued during the combustion process is transferred energy, as it enables users to customize it to their needs
via heat exchangers and provided to consumers. and avoids transmission losses. In areas with missing
The high efficiency of CHP systems enables up to or unreliable public infrastructure, MTU Onsite Energy
40 % reduction in primary energy usage compared to systems ensure independent power and heat supply.
conventional power systems.
// Reliable
Our gas power systems have proven their reliability,
availability and longevity in many applications and
over hundreds of thousands of operating hours.
Our advanced control technology ensures a high
availability rate for your system. Thanks to our
extensive service network, you will receive speedy
support from our experienced service partners –
anytime, anywhere.
With our MTU ValueCare portfolio, we provide
comprehensive service solutions which guarantee the
efficiency of your system in the long term.
MTU Onsite Energy / // / 5
CHP SYSTEMS:
PROVEN THOUSANDFOLD.
FOR A SECURE ENERGY SUPPLY.

Today’s energy production is mainly focused on fossil Common natural gas powered CHP applications are:
fuels. However, the limited supply of these fuels as well // Housing estates
as the negative impact that current technologies have on // Hospitals
the environment necessitate the rethinking of energy // Swimming pools
practices. // Industry and commerce
Gas powered energy systems offer great potential for // Hotels
playing an important role in the energy mix of the future // Schools
– and our gensets and modules can effectively explore // Public buildings
this potential. By deploying our gas engines, power, heat // Telecommunication centers
and cooling energy based on natural gas can be generated // Data centers
economically, eco-friendly and reliably. // Leisure centers
Our natural gas powered modules and gensets are // Shopping centers
technologically mature solutions combining highest // Greenhouses
performance with low emissions. They are used in many
different areas.
Whether in the municipal or the commercial sector –
we develop perfectly customized solutions for each
application.

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CHP SYSTEMS:
HIGHLY VERSATILE.
INDIVIDUALLY DIMENSIONED.
Building maintenance
Thanks to their reliability and efficiency, our CHP
systems are often deployed in the field of local heat
supply. There are convincing arguments for the use of
distributed energy supply systems powered by natural gas
– especially when it comes to the accommodation of
numerous buildings and housing units.
Local heat is an economically viable alternative to
separate heat generation in the individual buildings.
Its users benefit from various cost advantages. Besides
the lower specific investment costs, maintenance is less
complex and therefore more cost effective for one bigger
system than for various small ones. Additionally, users
gain space since a boiler plant in their own building is no
longer necessary. The CHP covers the heat requirement
base load economically, reliably and eco-friendly.
Heat storage and an additional peak load boiler enable a
flexible generation adaptation to the users’ heating
profi le.
8 / // / MTU Onsite Energy
Industry Safety-critical applications
Companies with a continuous demand for electricity and For safety-critical applications, for example in hospitals
heat for their production processes can benefit from or data centers, a continuous energy supply is essential.
cogeneration systems. Whether in food processing, Our gas engine systems have proven themselves many
chemical production or traditional manufacturing times. Depending on the legal requirements on site, our
processes, our CHP systems provide power, heat and cool- CHP modules can also take on emergency power
ing energy for the individual demands of industrial generator functions.
applications – efficiently and independently.
MTU Onsite Energy’s gas powered CHP modules are also
an interesting alternative if the capacities of production
facilities are to be extended. Instead of increasing line
capacities, you invest in a distributed, independent
energy solution. In order to enhance their production
processes profitability, more and more companies decide
for our CHP systems.
We will be happy to inform you about the possible
savings potential within your energy supply on the basis
of an economic efficiency calculation.
MTU Onsite Energy / // / 9
 ALL YOU NEED:
POWER. POWER AND HEAT.
POWER, HEAT AND COOLING ENERGY.

With our aggregates, modules and container solutions, we offer
different systems to supply basic power, power and heat generation
or even power, heat and cooling energy. Whatever application you
focus on – MTU Onsite Energy systems fulfi l your demands.
Power supply
Our gas gensets are frequently used for simple power generation,
guaranteeing a 24/7 security of supply at locations with unreliable
or missing electricity networks.
According to the demands, our systems can be used for grid-parallel
or off-grid operation.
Power and heat supply (CHP)
Many buildings and building complexes have a high demand for
heat and power. Hospitals, schools, sports facilities, office and
administrative buildings, department stores and shopping centers
often separately generate heat and obtain power from the public grid.
Energy modules from MTU Onsite Energy can provide a significantly
more economical alternative. The heat generated by our CHP systems
can be used not only for heating but also as process heat, e.g. in
industrial enterprises. Whether in the chemical industry or metal
processing, parallel power generation can increase the operating
efficiency.
Power, heat and cooling heat supply (CHPC)
Using an absorption chiller, CHP systems can also create cooling
energy with their generated heat - a flexibility that can, for example,
enable the climate control for a whole office block. The additional
costs for an absorber are low, and thanks to the longer lifespan, the
system’s operating efficiency can be further increased.
The supply of cooling energy plays an important role not only for
building climatization. It can be used in many other fields, such as
process cooling for manufacturing, food refrigeration, ambient
cooling in temperature sensitive areas (e.g. data centers) or building
maintenance. Consequently, the generation of cooling energy extends
the possibilities of using our CHP systems in a very cost effective
way. We will gladly provide you with a cost-benefit-analysis for your
individual application.

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GAS GENSETS
AND CHP MODULES:
PROVEN, EFFICIENT,
RELIABLE.
12 / // / MTU Onsite Energy
Gas gensets and modules from MTU Onsite Energy systems are
technologically advanced solutions with a high degree of electrical
Our gas modules and gensets for natural gas cover the power range
from 120 to 2,200 kWel. The selection of the right CHP system
efficiency. They have proven their reliability, availability and
longevity in many applications and hundreds of thousands of
depends on various factors. We will provide you with wide-ranging
support, all the way from the project idea to its realization.
operating hours.
// Our lean-burn engines prevent the production of harmful emissions
// Support in planning your new CHP module
// Explanation of how to incorporate the CHP module into your
in the actual combustion process itself. Emission levels below the
limits required by the German „TA Luft“ clean air regulations and
application
// Explanations of the technology behind the engine, system and
similar standards in other countries are reliably achieved even individual components
without the use of a catalytic converter. // Offer creation with budget price for planning phase and fi xed price
for implementation
// TheMTU Onsite Energy oxygen-content control system guarantees // Design and planning of peripheral systems
optimum combustion even with variable gas qualities, preventing // Advice on service solutions as early as the project phase
engine damage. // Help with questions on legal situations (EEG, formaldehyde bonus)
// Thearrangement of the cooling system enables straightforward We will gladly provide you with more information by telephone or
integration into existing heating systems. visit you for a personal meeting on site.
// Theexhaust heat exchanger is integrated into the engine coolant
circulation system, minimizing the risk of heat exchanger damage.
// Bythe use of largely standardized and carefully selected
subassemblies, maximum operational safety and reliability are
achieved. Availability figures of well over 90% are the norm with
MTU Onsite Energy systems.
// Low
fuel and lubricant consumption combined with long
component life reduce operating costs.
// Aseparate development department constantly analyzes the data
from the use of our systems in the field and optimizes the
technology on our test benches for a vast diversity of natural
gas application requirements.
MTU Onsite Energy / // / 13
COMPACT CHP SYSTEMS: MTU Onsite Energy has an advanced product program, with reliable
gas engines at its heart. Many of our systems have already completed
Compact modules not only offer high levels of electrical and thermal
efficiency with a fuel-efficiency level of up to 90 % and beyond, but

REQUIRES MINIMUM SPACE. well over 100,000 hours of service and still continue to reliably supply
heat and electricity day after day – conclusive proof of the dependability
also many other benefits.

PROVIDES MAXIMUM EFFICIENCY. of our engine technology.

We generally design CHP modules as multi-module systems so that

Series 400 overall system outputs of as much as 5 MWel can be achieved with
optimum efficiency. Adjustment to the electrical or thermal load
Output range 100 – 400 kWel profile is achieved by switching in or shutting down individual
modules. Another advantage of multi-module systems is their high
level of availability.
Our compact module technology is based on the economical principle
of optimizing both output and benefit. Over 2,500 CHP modules in use
worldwide are proof of that.
MTU Onsite Energy’s compact modules are:
// Space-saving
// Supplied ready to connect
// Factory tested
// Available as uncovered or enclosed units
// Easy to maintain
When planning distributed energy systems using CHP modules, the
question of additional use as a grid backup or emergency power
generator often arises. With synchronous generator and starter
battery, our modules are fundamentally suitable for emergency power
generation. All hard- and software adaptations necessary within the
module control and monitoring will be carried out after technical
clarification with the operator.

7 2 6 4 1 3 5
Description of individual components

1 Gas engine 5 Knock detection

// Advanced and proven Series 400 gas engine, optimized
for natural gas use. Combustion chambers ensure the
highest level of efficiency in this performance category.
2 Generator
// Optimally tailored to the engine and made by renowned
manufacturers, the generator ensures a high level of
reliability with the best degree of efficiency.
3 Ignition system
// Ignition systems for individual cylinders allow for the
most efficient level of operation for all cylinders, even
with variable CH4 content. The ignition voltage display
gives customers information about the state of the
spark plugs.
4 Mixture cooler
// The two-stage mixture cooler with large surface area
improves engine performance and heat utilization.
// Cylinder-specific knock detection and regulation
protects the engine from abnormal operating
conditions and guarantees safe operation even with
natural gas, which contains high levels of methane.
6 Crank-case ventilation
// Improved crank-case ventilation minimizes deposits in
intake tract and combustion chamber and guarantees a
continuously high level of performance.
7 MTU Module Control (MMC)
// The MTU Module Control (MMC) contains all the
important functions necessary for controlling the
system. All the auxiliary drives required for the CHP
system can be operated from here. The integrated
power circuitry minimizes the need for cabling on site.

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 SPLIT-CONFIGURATION CHP SYSTEMS:
GREAT PERFORMANCE.
GREAT FLEXIBILITY.
Series 4000
Output range 750 – 2,200 kWel

Energy modules and generator sets for outputs up to 2,200 kWel
per unit complete the MTU Onsite Energy range of natural gas
CHP systems.
Unlike the small series modules, these systems are supplied as
split-configuration installations rather than as compact modules.
This means that the engine-and-generator set and the heat module
are made as separate units.
With the sizes that are required for the high outputs involved,
our split configuration offers greater benefits for the operator.
Advantages of MTU Onsite Energy split-configuration modules:
// Separation of the heat generation module
// Individual modification to customers’ requirements
// Optimal adaptation to the space available at the installation site
// Optional warm-water generation with various temperature ranges
as well as steam generation with separate waste heat utilization
// Easily transportable
// Simplified installation
Like the compact modules, the engine-and-generator sets are
comprehensively factory tested before delivery to the client.

2 4 3 1 5 6
Description of individual components

1 Gas engine 5 Knock detection

// Advanced and proven Series 4000 gas engine, // Cylinder-specific knock detection and regulation
optimized for natural gas use. Combustion chambers protects the engine from abnormal operating
ensure the highest level of efficiency in this conditions and guarantees safe operation even with
performance category. natural gas, which contains high levels of methane.

2 Generator 6 Crank-case ventilation

// Optimally tailored to the engine and made by renowned // Improved crank-case ventilation minimizes deposits in
manufacturers, the generator ensures a high level of intake tract and combustion chamber and guarantees a
reliability with the best degree of efficiency. continuously high level of performance.

3 Ignition system MTU Module Control (MMC)

// Ignition systems for individual cylinders allow for the
most efficient level of operation for all cylinders, even
with variable CH4 content. The ignition voltage display
gives customers information about the state of the
spark plugs.
4 Mixture cooler
// The two-stage mixture cooler with large surface area
improves engine performance and heat utilization.
// TheMTU Module Control (MMC) contains all the
important functions necessary for controlling the
system. All the auxiliary drives required for the CHP
system can be operated from here. The integrated
power circuitry minimizes the need for cabling on site.
The MMC is housed separately in the control cabinet
and is therefore hidden from sight.

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 CONTAINER UNITS:
GENERATING ENERGY
WHEREVER YOU WANT.
As a system supplier, we offer a wide variety
of solutions. In addition to our gas engine
systems for use in buildings, we also provide
containerized turnkey units. Compact,
complete, flexible and autonomous, they are
ideally suitable for mobile power generation or
for applications that do not provide enough
space for the insertion of a complete gas
engine system.
When producing electricity from natural gas,
installing the generator set in a container
can be a useful alternative to the more
common option of permanently installing
a static system in a generator room.
Our standardized container genset is
designed to meet the requirements of a
variety of applications.
18 / // / MTU Onsite Energy
The container includes:
// The generator set
// The switchgear including control and
monitoring system
// All necessary connection and supply
systems (ventilation, lubricant supply,
heat recovery, etc.)
Like all MTU Onsite Energy systems, the
standard container gensets are capable of
fully automatic and continuous operation.
The systems start up on their own whenever
there is an adequate quantity of gas available
with a minimum methane content, and shut
down again automatically when the gas
supply is insufficient.
We offer two types of containers for different
requirements:
// Power Containers generate only electrical
energy and are ideal for remote locations or
areas with unreliable power supply.
// Combined heat and power units (CHP)
generate electrical and thermal energy, e.g.
for operators whose processes require heat
in addition to power.
Your advantages:
// Technically mature, proven and eco-friendly
gas engine technology for maximum
efficiency and reliability
// Completely autonomous overall design that
does not require any additional buildings
// Flexible unit assembly system based on
standardized modules and synchronized
components
// Readily available, compact turnkey plug &
play solutions
// Optimal support thanks to a worldwide
service network
// Quality certified under ISO 9001 and
DIN EN ISO 14001
MTU Onsite Energy / // / 19
MTU ONSITE ENERGY:
ONE FOR ALL.
MTU Onsite Energy is your system partner. This means
that as well as supplying the actual module or genset,
we offer you a whole range of perfectly developed system
components.
Oxidation catalyst
Tailored to the respective engine, the catalyst guarantees
adherence to specific emissions standards.
Auxiliary drive control and electrical connections
The integrated MMC (MTU Module Control) offers a
range of connections and control options, such as hot
water pumps, mixed cooling water pumps, extractor fan
control, gas warning system, lubricant system, smoke
detector and gas compressor.
Gas safety plan
MTU Onsite Energy has developed a comprehensive gas
safety plan for entire systems. The plan guarantees
protection against internal and external explosions and
has been tested by the TÜV. Talk to us – our specialists
will be happy to advise you.
20 / // / MTU Onsite Energy
CHP MODULE CONTROLLER:
THE BRAINS OF THE SYSTEM.
MTU Onsite Energy supplies you with the complete system
engineering package for your installation. One of the most important
aspects is the control system technology, which comes standard when
you buy from us. If the generator set is the “heart” of the system, then
the module controller is its “brain”. Our industrial-computer controlled
and reliable electronics monitor the engine and the overall system to
ensure optimum operation.
The most important features are:
// Control via RPS
// Operation and visual display by means of industrial PC and
touch-screen panel with colour display
// Visual display of all functional processes and controls
// Numerous additional controls and functions can be integrated
(CH4, gas tank, heat production mode, heat storage, mains
power usage)
// Networking of multi-module systems via Ethernet
// Can be linked to master control systems
// Wide choice of interface protocols (Ethernet, Profibus DP, 964R,
Modbus RTU)
// Logging of all fault and status messages in a database
(up to six months of data can be recorded)
// Optional remote diagnosis via ISDN
// Optional integration of SMS / E-mail client (notification of faults,
daily reporting of all meter readings)
MTU Onsite Energy / // / 21
 MTU VALUECARE:
SUPERIOR SERVICE
FOR LONG SYSTEM LIFE
AND TOP PERFORMANCE.

Purchasing a gas power system from
MTU Onsite Energy pays off in many ways:
not just by its performance and reliability,
but also because of the security you get from
our superior service.
The demands on complete systems for electricity
and heat production are high.
We are committed to offering the best services
and maintenance solutions. With that as our
goal, we offer you a portfolio of services that goes
above and beyond the technology itself –
MTU ValueCare.
MTU ValueCare is perfectly developed
for your cogeneration system, helping to
maximize its availability and efficiency.
The three main product lines of
MTU ValueCare are:
ValueService
Our service program ValueService
encompasses solutions for maintenance,
training, documentation and repairs, which
MTU Onsite Energy tailors specifically to
your CHP systems and to meet your needs.
// With our individually tailored service
contracts, repair contracts, maintenance
contracts and inspection contracts for
any system, you can save costs over the
whole life cycle of the unit, increase the
availability rate and avoid individual repairs.
// Our training courses for gas power
systems are taught by highly-qualified and
experienced instructors. Courses are
conducted in our training centers or at your
facility. MTU Onsite Energy training programs
make operating staff proficient with
MTU Onsite Energy engines and systems.
ValueSpares
Our genuine MTU spare parts and top-quality
consumables are perfectly tailored to your
CHP system and ensure the continued peak
performance of your MTU Onsite Energy
cogeneration systems.
ValueExchange
Our ValueExchange program incorporates a
basic overhaul of the engine as well as the
refurbishment of components and parts.
Remanufactured engines and parts have the
same appearance, the same life expectancy
and the same performance as new products.
Most also enjoy warranties similar or identical
to their new counterparts.
Our ValueExchange program is a cost-
effective alternative to new engines and parts.

// With our diagnostic solution, Remote Services,

you’ll have direct access to the activity of your
cogeneration systems – no matter where you
are. You can receive predefined operational
reports by E-mail or SMS to ensure that you
are always well informed. Remote Services
also provides the ideal basis for operational
decisions and guarantees optimal utilization.

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 3061561 | 1/12 | VMC 2012-03 B | Printed on chlorine-free paper. Subject to alteration due to technological advances.

MTU Onsite Energy GmbH

Gas Power Systems / Dasinger Strasse 11 / 86165 Augsburg / Germany / Phone +49 (821) 7480-265 / Fax +49 (821) 7480-259 / info-oeg@mtu-online.com

A TOGNUM GROUP COMPANY

www.mtu-online.com