Product Specifications POWERBLOCK GENERATION SYSTEMS EPA Tier 2/Tier 4 Final Certified PowerBlock Systems Ratings: 600 kw/750 kva to 3125 kw/3910 kva 208V to 480V at 60 Hz
2 Patented Design The PowerBlock product family consists of integrated generation paralleling systems that feature EPA certified engines equipped with all required accessories. Our uniquely modular PowerBlock design includes power ratings from 600 kw to 3125 kw and the flexibility to add additional power over time. Gensets are UL 2200 listed and the enclosures are UL 2200 classified. Engine Our 16-liter Volvo engines are powerful, reliable and economical diesel engines built on the dependable in-line six design. Each engine is well balanced to produce smooth operation with low noise levels and utilizes replaceable cylinder liners and valve seats/guides to ensure maximum durability and service life. The state-of-the-art, high-tech injection and air charging system with low internal losses contributes to the engine s excellent combustion and low fuel consumption. Service and maintenance points are easily accessible, contributing to the engine s overall low cost of ownership. AC Generator PowerBlock systems are available with a selection of quality AC generators matched to the engine and our customer s site-specific requirements. To ensure quality and minimize installation and startup times, all systems undergo complete factory performance testing before shipment. System Controls NexGear switchgear includes the engine interface, all paralleling controls and applicable protection for both the engine and the generator. Our controls are tailored to provide a complete paralleling power system available from a single source. Enclosure/Fuel Tank PowerBlock enclosures come standard with a welded aluminum frame, aluminum skin and stainless steel exterior hardware. The construction has been analyzed to withstand 150 MPH wind loading. Pre-engineered options are available in multiple sound attenuation levels. Additional colors and options are also available. UL 142-listed sub-base fuel tanks are standard. Tanks come with 24-hour storage capacity, interstitial rupture basin switches, level indication, venting and engine fittings. Fuel transfer, polishing, state-specific code requirements and day-tank systems are also available.
3 SPECIFICATIONS Generator PMG excitation 4 poles Single bearing 12 winding leads, 2/3 pitch Class H insulation system Enclosure protection rating IP23 Max overspeed of 2250 rpm (125% rated) Efficiency > 95% Harmonic distortion < 5% Telephone Influence Factor (TIF) < 50 300% short circuit capability for 10 seconds Paralleling Generator Controller Applications - Standby - Peak shaving - Import-export - Island parallel - Mains parallel - Multiple unit mains parallel Operation modes - Auto - Stop - Manual - Load/no load test Load transfer features - Open/closed transition - Soft loading/unloading - Parallel Bore, mm (in): 144 (5.67) Controls - Voltage adjust - Frequency adjust - VAR/power factor control GCB and MCB synchronization Stroke, mm (in): 165 (6.50) Remote annunciator modules (NFPA 99/110) Displacement L (in3): 16.12 (983.9) Local annunciator modules (NFPA 99/110) Engine In-line 6-cylinder diesel 4-cycle Dual stage turbo with intercoolers Electronic engine management (CAN J1939) 24VDC starting motor Output Breaker Dual fuel filters including water separator and water-in-fuel indicator/alarm Circuit breaker, UL listed, 3 pole, 100% 80A 24VDC engine driven alternator Electrically operated Circulating pump-style jacket water heater 10A battery charger with equalization and NFPA 110 alarm outputs Shunt trip and aux contacts
4 TECHNICAL APPLICATION DATA FUEL CONSUMPTION 1 (with fan) 100% 75% 50% 25% LUBE OIL CONSUMPTION Tier 2 (TWD1643GE) Tier 4 Interim 2 (TWD1663GE) Tier 4 Final (TWD1673GE) Tier 4 Interim 2 (TWD1663GE) Tier 4 Final (TWD1673GE) g/kwh gal/hr g/kwh gal/hr g/kwh gal/hr g/kwh gal/hr L/hr gal/hr 204 40 198 29 195 19 210 10 0.11 0.029 204 41 196 30.5 200 20 218 12 0.11 0.029 197 43 195 32 201 22 223 12 0.11 0.029 DEF CONSUMPTION 100% 75% 50% 25% % fuel gal/hr % fuel gal/hr % fuel gal/hr % fuel gal/hr 2.3 0.94 3.0 0.92 3.4 0.68 3.2 0.38 6.1 2.62 7.2 2.30 6.7 1.47 6.6 0.79 COOLING SYSTEM Max ambient Fan air flow Engine coolant Radiator capacity Expansion tank Max allowed air (open skid) (open skid) capacity (w/piping) capacity flow restriction 3 Tier 2 (TWD1643GE) Tier 4 Interim 2 (TWD1663GE) Tier 4 Final (TWD1673GE) C F m 3 /min SCFM L Gal L Gal L Gal kpa inh 2 O 50 122 900 31,780 33 8.7 62 16.4 27 7.1 0.125 0.5 50 122 912 32,207 33 8.7 48 12.7 27 7.1 0.125 0.5 50 122 912 32,207 33 8.7 48 12.7 27 7.1 0.125 0.5 INLET AIR EXHAUST SYSTEM LUBE SYSTEM Combustion air Exhaust gas Exhaust gas Max allowable inlet flow temperature flow rate back pressure Total capacity with filters Tier 2 (TWD1643GE) Tier 4 Interim 2 (TWD1663GE) Tier 4 Final (TWD1673GE) m 3 /min SCFM C F m 3 /min SCFM kpa PSI L Gal 55 1937 461 862 130.1 4593 10 1.5 48 12.7 53 1858 478 892 124 4379 13 1.9 48 12.7 51 1805 484 903 137.8 4866 10 1.4 48 12.7 ALTERNATOR HEAT REJECTION Rise/over ambient To coolant To exhaust Radiation from engine Tier 2 (TWD1643GE) Tier 4 Interim 2 (TWD1663GE) Tier 4 Final (TWD1673GE) C F kw BTU/min kw BTU/min kw BTU/min 125/40 257/104 405 23,032 530 30,141 33 1877 125/40 257/104 461 26,217 502 28,548 29 1649 125/40 257/104 461 26,217 521 29,623 29 1649 1 Fuel consumption based on 6.8 lb/gal ultra-low sulfur #2 diesel fuel with a caloric value of 18,360 BTU/lb and a density of 7.01 lb/us gal (0.84 kg/liter) operating at sea-level static conditions. 2 Applicable only to PowerBlock Mobile units. 3 Open skid
5 POWER RATINGS OVERALL PACKAGE OUTPUT Tier 2 Engines Emergency standby Prime Limited-time running Continuous 1 600 560 540 450 2 1200 1120 1080 900 3 1800 1680 1620 1350 4 2400 2240 2160 1800 5 3000 2800 2700 2250 Tier 4 Interim 1 & Tier 4 Final Engines Emergency standby Prime Limited-time running Continuous 1 625 560 540 470 2 1250 1120 1080 940 3 1875 1680 1620 1410 4 2500 2240 2160 1880 5 3125 2800 2700 2350 POWER RATING DEFINITIONS (based on ISO 8528) Load Factor (% of max output) Max annual hours Definition Emergency standby (ESP) Prime (PRP) Limited-time running (LTP) Continuous (COP) 70% 200 70% Unlimited 100% 500 100% Unlimited Available with variable load for 200 hours per year. Average load not to exceed 70% of standby rating. Available with variable load for unlimited hours. Average load not to exceed 70% of prime rating. Available without variable load for 500 hours per year. Available without variable load for unlimited hours. 1 Applicable only to PowerBlock Mobile units.
6 ANATOMY OF A POWERBLOCK ON-BOARD DEF TANK GENERATOR GEAR: ADVANCED PARALLELING SWITCHGEAR TIE-SECTION GEAR: SINGLE CUSTOMER CONNECTION POINT OPTIONAL: EXTENDED DEF CAPACITY HOUSE POWER TRANSFORMER & DISTRIBUTION DIESEL ENGINE AVAILABLE IN T2 AND T4F
7 SLOPED ROOF WITH INTEGRAL GUTTERS OPTIONAL: SOUND ATTENUATION INTAKES STANDARD: SOUND ATTENUATION UPDRAFT DISCHARGE FACTORY CERTIFIED SCR (NO DPF) AFTER TREATMENT ON T4F DROP-OVER ENCLOSURE: WELDED ALUMINUM FRAME WITH ALUMINUM SKIN. STAINLESS STEEL HARDWARE. UL 2200 CLASSIFIED UL 142 SUB-BASE FUEL TANK
8 DIMENSIONS PACKAGED UNITS Engines Level db(a)** L (in) W (in) H (in) Dry WT (lb) Wet WT (lb) L1 85 253 102 148 25,500 34,000 Single L2 78 313 102 131 26,000 35,000 L3 72 373 102 171 29,000 38,000 Dual* L1 85 409 102 169 50,000 67,000 L2 78 409 94 217 52,000 69,000 L1 85 410 201 169 58,000 78,000 3-engine modular L2 78 410 247 169 59,000 80,000 L3 72 455 393 174 70,000 91,000 L1 85 511 201 169 74,000 102,000 4-engine modular L2 78 511 247 169 78,000 104,000 L3 72 571 393 174 90,000 116,000 L1 85 612 201 169 95,000 130,000 5-engine modular L2 78 612 247 169 98,000 133,000 L3 72 687 393 174 110,000 145,000 *Dual configuration includes end-to-end generators. **Sound data per ISO 8528-10; free field environment @ 7m (23 ) OPEN SKID UNIT Engines L (in) W (in) H (in) Dry WT (lb) Wet WT (lb) 1 72 215 124 14,000 15,000 2 143 215 124 28,000 30,000 3 215 215 124 42,000 45,000 4 286 215 124 56,000 60,000 5 358 215 124 70,000 76,000 SPECIFICATIONS AND STANDARDS CSA C22.2-100 IEC34 ISO 3046 ISO 8528 NEC (NFPA 70e) NEMA MG1-32 NFPA 110 UL 142 UL 891 UL 2200
21 13 16 SINGLE 1 313 9 C C 131 102 DOUBLE 2 409 169 102 MODULAR 3-5 3 612 169 247 1 L2 shown 2 L1 shown 3 L1 shown
For reference only. Please contact one of our technical sales professionals. Materials and specifications are subject to change without notice. PowerSecure 1609 Heritage Commerce Court Wake Forest, NC 27587 Phone: 919-556-3056 Fax: 919-556-3596 PowerSecure.com DGinfo@PowerSecure.com v2 2016