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.
Image shown may not reflect actual package

FEATURES

EMISSIONS Cat® G3520C GAS ENGINE

• Meets most worldwide emission levels • Robust high speed diesel block design provides
down to 0.5 g/bhp-hr (250 mg/Nm3) Nox prolonged life and lower owning and operating costs
level without after treatment • Designed for maximum performance on
low pressure gaseous fuel supply.
FULL RANGE OF ATTACHMENT • Simple open chamber combustion system for
• Wide range of bolt-on system expansion reliability and fuel flexibility.
attachments, factory designed and tested. • Leading edge technology in ignition system
• Flexible packaging options for easy and cost and air/fuel ratio control for lower emission
effective installation. and engine efficiency
• One electronic control module handles all
PROVEN SYSTEM engine functions: ignition, governing, air/fuel
• Fully prototype tested. ratio control and engine protection
• Field proven in a wide range of applications
worldwide. CAT SR4B GENERATOR
• Certified torsional vibration analysis available • Designed to match performance and output
characteristics of Cat gas engines
WORLDWIDE PRODUCT SUPPORT • 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 S•O•S 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 Standard Optional
Gas Engine Control Fuel/air ratio control;
Module (GECM) 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
Air Inlet Two element, single-stage air cleaner with enclosure and Air cleaner with precleaner; Mounting stand
service indicator
Control Panel EMCP II+
Local alarm module; Remote annunciator;
Communications Module (PL1000T, PL1000E)
Synchronizing module; Engine failure relay
Cooling ANSI/DN customer flange connections for JW inlet and outlet Coolant level drain line with valves, fan with guard;
Cat flanges on SCAC circuit Inlet/Outlet connections.
Exhaust Dry exhaust manifolds, insulated and shielded; Flange; Exhaust expander; Elbow; Flexible fitting;
Center section cooled turbocharger with Cat flanged outlet; Muffler and spark-arresting muffler with companion
Individual exhaust port and turbocharger outlet wired to flanges.
Integrated Temperature Sensing Module (ITSM) with GECM
providing alarms and shutdowns.
Fuel Electronic fuel metering valve; Fuel filter;
Throttle plate, 24V DC actuator, controlled by GECM; Gas pressure regulator;
3
Fuel system is sized for 31.5 to 47.2 MJ/Nm (800 to 1200 Gas shutoff valve, 24V, ETR (Energized-To-Run)
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.
Generator SR4B generator, includes: Medium and high voltage generators and attachments;
Cat Digital Voltage Regulator (Cat DVR) with 3-phase Low voltage extension box; Cable access box;
sensing and KVAR/PF control; Reactive droop; Air filter for generator; Bearing temperature detectors;
Bus bar connections; Winding temperature detectors; Manual voltage control; European bus bar.
Anti-condensation space heater.
Governing Electronic speed governor as part of GECM; Woodward load sharing module
Electronically-controlled 24V DC actuator connected to
throttle shaft.
Ignition Electronic Ignition System controlled by GECM;
Individual cylinder Detonation Sensitive Timing (DST)
Lubrication Lubricating oil; Gear type lube oil pump; Oil filter, filler and dipstick; Oil level regualtor; Prelube pump;
Integral lube oil cooler; Oil drain valve; Crankcase breather. Positive crankcase ventilation system
Mounting 330 mm structural steel base (for low and medium voltage units);
Spring-type anti-vibration mounts (shipped loose)
Starting / Charging 24V starting motors; Battery with cables and rack (shipped loose); Charging alternator; Battery charger;
Battery disconnect switch; Oversized battery; Jacket water heater;
60A, 24V charging alternator (standard on 60Hz 1800rpm only)
General Paint -- Caterpillar Yellow except rails & radiators; Crankcase explosion relief valve;
Damper guard. Engine barring group;
Operation and Maintenance Manuals; Parts Book. EEC D.O.I and other certifications

LEHE2833-02 2
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
Consult your Cat dealer for all available Coolant temperature
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 3
CONTINUOUS 2000 ekW 2500 kVA
50 Hz 1500 RPM

TECHNICAL DATA

G3520C Gas Generator Set DM 5844 DM 5847 DM5849 DM5838 DM5840 DM5842

3
Emission level (NOx) mg/Nm 500 350 250 500 350 250
Aftercooler SCAC (Stage 2) Deg C 32 32 32 54 54 54
Package Performance (1)
Power Rating @ 0.8 pf ekW Continuous 2000 2000 2000 2000 2000 2000
(without water pumps and without fan)
Power Rating @ 0.8 pf kVA Continuous 2500 2500 2500 2500 2500 2500
(without water pumps and without fan)
Power Rating @ 1.0 pf ekW Continuous 2020 2020 2020 2020 2020 2020
(without water pumps and without fan)
(2)
Electric Efficiency @ 1.0 pf (ISO 3046/1) % 40.5 39.8 39.4 40.5 39.9 39.6
Mechanical Power bkW 2070 2070 2070 2070 2070 2070
(without water pumps and without fan)
Fuel Consumption (3)
3
100% load w/o fan Nm /hr 505 513 518 504 512 516
3
75% load w/o fan Nm /hr 389 396 400 387 393 396
3
50% load w/o fan Nm /hr 271 276 279 269 273 276
Altitude Capability (4)
At 25° C (77° F) ambient, above sea level m 390 298 238 250 250 250
Cooling System
Ambient air temperature Deg C 25 25 25 25 25 25
Jacket water temperature ( Maximum outlet ) Deg C 90 90 90 90 90 90
Exhaust System
3
Combustion air inlet flow rate Nm /min 145 149 151 147 150 152
Exhaust stack gas temperature Deg C 449 449 457 453 456 458
3
Exhaust gas flow rate Nm /min 154 154 160 156 159 161
Exhaust flange size ( internal diameter ) mm 328 328 328 328 328 328
Heat Rejection (5)
Heat rejection to JW, oil cooler and AC - Stage 1 kW 1040 1050 1055 1074 1094 1108
Heat rejection to AC - Stage 2 kW 197 200 202 126 131 134
Heat rejection to exhaust (LHV to 25° C) kW 1679 1750 1797 1712 1762 1793
Heat rejection to exhaust (LHV to 120° C) kW 1190 1239 1270 1219 1254 1274
Heat rejection to atmosphere from engine kW 125 125 125 125 125 125
Heat rejection to atmosphere from generator (Typical) kW 64 64 64 64 64 64
Lubrication System
Standard sump refill with filter change L 541 541 541 541 541 541
(7)
Emissions
3
NOx @ 5% O2 (dry) mg/Nm 500 350 250 500 350 250
3
CO @ 5% O2 (dry) mg/Nm 971 962 957 1043 998 968
3
THC @ 5% O2 (dry) mg/Nm 2675 2899 3048 2643 2768 2851
3
NMHC @ 5% O2 (dry) mg/Nm 402 435 458 397 416 428
Exhaust O2 (dry) % 9.3 9.6 9.7 9.4 9.5 9.5

LEHE2833-02 4
CONTINUOUS 2000 ekW 2500 kVA
50 Hz 1500 RPM

TECHNICAL DATA

G3520C Gas Generator Set DM 5845 DM 5848 DM5850 DM5839 DM5841 DM5843

3
Emission level (NOx) mg/Nm 500 350 250 500 350 250
Aftercooler SCAC (Stage 2) Deg C 32 32 32 54 54 54
Package Performance (1)
Power Rating @ 0.8 pf ekW Continuous 2000 2000 2000 2000 2000 2000
(without water pumps and without fan)
Power Rating @ 0.8 pf kVA Continuous 2500 2500 2500 2500 2500 2500
(without water pumps and without fan)
Power Rating @ 1.0 pf ekW Continuous 2020 2020 2020 2020 2020 2020
(without water pumps and without fan)
Electric Efficiency @ 1.0 pf (ISO 3046/1) (2) % 40.6 39.9 39.5 40.5 39.9 39.6
Mechanical Power bkW 2070 2070 2070 2070 2070 2070
(without water pumps and without fan)
Fuel Consumption (3)
3
100% load w/o fan Nm /hr 504 512 518 504 512 516
3
75% load w/o fan Nm /hr 389 395 400 387 393 396
3
50% load w/o fan Nm /hr 271 275 278 269 273 276
Altitude Capability (4)
At 25° C (77° F) ambient, above sea level m 390 298 238 350 350 350
Cooling System
Ambient air temperature Deg C 25 25 25 25 25 25
Jacket water temperature ( Maximum outlet ) Deg C 99 99 99 99 99 99
Exhaust System
3
Combustion air inlet flow rate Nm /min 146 149 152 147 149 156
Exhaust stack gas temperature Deg C 450 456 459 446 468 469
3
Exhaust gas flow rate Nm /min 155 158 161 155 158 160
Exhaust flange size ( internal diameter ) mm 328 328 328 328 328 328
Heat Rejection (5)
Heat rejection to JW, oil cooler and AC - Stage 1 kW 985 994 999 1011 1030 1042
Heat rejection to AC - Stage 2 kW 227 230 232 155 160 184
Heat rejection to exhaust (LHV to 25° C) kW 1684 1756 1802 1733 1784 1815
Heat rejection to exhaust (LHV to 120° C) kW 1198 1247 1279 1257 1293 1314
Heat rejection to atmosphere from engine kW 138 138 138 138 138 138
Heat rejection to atmosphere from generator (Typical) kW 64 64 64 64 64 64
Lubrication System
Standard sump refill with filter change L 541 541 541 541 541 541
Emissions (7)
3
NOx @ 5% O2 (dry) mg/Nm 500 350 250 500 350 250
3
CO @ 5% O2 (dry) mg/Nm 981 973 968 1035 990 960
3
THC @ 5% O2 (dry) mg/Nm 2633 2855 3002 2381 2493 2567
3
NMHC @ 5% O2 (dry) mg/Nm 395 429 451 358 374 386
Exhaust O2 (dry) % 9.4 9.7 9.8 9.2 9.3 9.4

LEHE2833-02 5
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
3 3
(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.

LEHE2833-02 6
 CONTINUOUS 2000 ekW 2500 kVA
50 Hz 1500 RPM

DIMENSIONS

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

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 www.Cat-ElectricPower.com
DM5847, DM5848 © 2011 Caterpillar
DM5849, DM5850 All rights reserved.
Materials and specifications are subject to change without notice.
Feature Codes: 520GE24, 520GE25
The International System of Units (SI) is used in this publication
520GE26, 520GE27 CAT, CATERPILLAR, their respective logos,
520GE47, 520GE48
"Caterpillar Yellow," the "Power Edge" trade dress as well
520GE49, 520GE50
as corporate and product identity used herein, are trademarks
Source: US Sourced
of Caterpillar and may not be used without permission.
LEHE2833-02 (05-11)
LEHE2833-02 7