Fluids and Lubricants

Specifications
Gas engines and gas engine-generator sets
Series 4000 gas engine – marine application
Series 4000 gas engine – generator application and engine-generator
set
Series 400 gas engine – engine-generator set
Series 500 gas engine – engine-generator set

A001072/06E
Rolls-Royce Solutions refers to Rolls-Royce Solutions GmbH or an affiliated company pursuant to §15 AktG (German Stock
Corporation Act) or a controlled company (joint venture), and Rolls-Royce Solutions Ruhstorf GmbH.

© Copyright Rolls-Royce Solutions

This publication is protected by copyright and may not be used in any way, whether in whole or in part, without the prior writ-
ten consent of Rolls-Royce Solutions. This particularly applies to its reproduction, distribution, editing, translation, microfilming
and storage and/or processing in electronic systems including databases and online services.
All information in this publication was the latest information available at the time of going to print. Rolls-Royce Solutions re-
serves the right to change, delete or supplement the information provided as and when required.
 Table of Contents
1 Preface 3.2.2 Coolants without antifreeze – Concentrates for
cooling systems free of light metal 44
1.1 General information 5 3.2.3 Coolant without antifreeze – Ready mixtures
for cooling systems free of light metal 46
2 Lubricants 3.2.4 Antifreeze – Concentrates for cooling systems
free of light metal 47
2.1 General Information 7 3.2.5 Antifreeze – Concentrates for special
2.1.1 Engine oil 7 applications 50
2.1.2 Engine oil limit values for Series 4000 and 3.2.6 Antifreeze – Ready mixtures for cooling
Series 400 8 systems free of light metals 51
2.1.3 Engine oil limit values Series 500 10
2.1.4 Silicon compounds in the fuel gas 11
3.3 Series 4000 gas engine – Generator
2.1.5 Fluorescent dyestuffs for detecting leaks in the application and engine-generator set 53
lube oil circuit 12 3.3.1 Coolant – General information 53
2.1.6 Lubricating greases 13 3.3.2 Coolant without antifreeze – Concentrates for
2.1.7 Lubricating greases for general applications 14 cooling systems containing light metal 54
3.3.3 Coolant without antifreeze – Ready mixtures
2.2 Series 4000 gas engine – Generator for cooling systems containing light metal 55
application and engine-generator set - 3.3.4 Antifreeze – Concentrates for cooling systems
marine application 15 containing light metal 56
2.2.1 Approved engine oils 15 3.3.5 Antifreeze – Concentrates for special
2.2.2 Lubricating greases for generators 18 applications 60
2.2.3 Gear oils 19 3.3.6 Antifreeze – Ready mixtures for cooling
systems containing light metals 61
2.3 Series 400 gas engine – Engine-generator
set 20 3.4 Series 400 gas engine – Engine-generator
2.3.1 Approved engine oils 20 set 64
2.3.2 Engine oil change intervals 23 3.4.1 Approved coolants 64
2.3.3 Lubricating greases for generators 25
3.5 Series 500 Gas Engine - Engine-Generator
2.4 Series 500 Gas Engine - Engine-Generator Set 65
Set 26 3.5.1 Coolants – General information 65
2.4.1 Approved engine oils 26 3.5.2 Coolant – Check and replacement 66
2.4.2 Engine oil change intervals 27 3.5.3 Approved coolants 67
2.4.3 Oil volume 28
2.4.4 Lubricating greases for generators 29
4 Fuels

3 Coolants 4.1 General Information 68

4.1.1 Fuels – Usage 68
3.1 General Information 30 4.1.2 Requirements for fuel gas 69
3.1.1 Coolant – Definition 30 4.1.3 Main constituents of natural gas and fuel
3.1.2 Operational monitoring / coolant conditioning gases of biogenic origin 70
for Series 4000 and 400 engines 32 4.1.4 Liquid Natural Gas (LNG) 71
3.1.3 Coolant concentrates – Storage capability 36 4.1.5 Silicon and sulfur compounds in the fuel gas 72
3.1.4 Color additives to detect leakage in the coolant
4.2 Series 4000 gas engine – Marine application 73
DCL-ID: 0000047995 - 009

circuit 37
4.2.1 General 73
3.1.5 Preventing damage to cooling system 38
4.2.2 Requirements of fuel gas for marine
3.1.6 Unsuitable materials in the coolant circuit 39
applications 74
3.1.7 Fresh water requirements – Series 4000 40
4.2.3 Specifications for the medium in the gas
3.1.8 Fresh water requirements – Series 400 41
piping leak chamber for marine applications 77
3.1.9 Fresh water requirements Series 500 42
4.3 Series 4000 gas engine – Generator
3.2 Series 4000 gas engine – Marine application 43
3.2.1 Coolant – General information 43
application and engine-generator set 79
4.3.1 General 79
4.3.2 Natural gas – Requirements of the fuel gas 80

A001072/06E 2022-03 | Table of Contents | 3

 4.3.3 Biogas – Requirements for fuel gas 83 6.2.1 General information 108
6.2.2 Approved cleaning agents 109
4.4 Series 400 gas engine – Engine-generator 6.2.3 Engine cooling system – Cleaning 110
set 87
4.4.1 Natural gas – Fuel values 87
4.4.2 Biogas – Fuel values 88 7 Inlet Air and Combustion Air
4.4.3 Harmful impurities (pollutants) 89
7.1 General information 111
4.5 Series 500 Gas Engine - Engine-Generator 7.2 Humidity 112
Set 91 7.3 Dust load 113
4.5.1 Gas types 91
4.5.2 Minimum requirements of gas composition 92
4.5.3 Gas operating data 93 8 Heating Water
4.5.4 Conversion of limit values from gas analysis 94
8.1 General information 114
4.5.5 Special limit values 95
4.5.6 Operational malfunctions due to condensate in
8.2 Information on heating water for Series
the fuel gas 97 4000 and 400 115
8.3 Information on Heating Water for Series
500 Engines 117
5 Exhaust Gas Aftertreatment System 8.3.1 Water quality for heating water circuit Series
500 117
5.1 General 98 8.3.2 Heating water – Water quality Series 500 118
5.2 NOx reducing agent AUS 32 for SCR
exhaust gas aftertreatment systems 99
5.3 Exhaust condensate 101 9 Confirmation for Fluids and Lubricants
9.1 Confirmation by the operator of engine-
6 Flushing and Cleaning Specifications for generator sets 119
Engine Coolant Circuits
6.1 Flushing and Cleaning Specifications for 10 Revision Overview
Series 400 and 4000 Engines 102
10.1 Revision overview 120
6.1.1 General information 102
6.1.2 Approved cleaning agents 103
6.1.3 Engine coolant circuits – Flushing 104 11 Appendix A
6.1.4 Engine coolant circuits – Cleaning 105
6.1.5 Cleaning engine coolant circuit assemblies 106
11.1 List of abbreviations 121
6.1.6 Coolant circuits contaminated with bacteria, 11.2 Conversion table of SI units 122
fungi or yeast 107 11.3 Contact person/Service partner 123
6.2 Flushing and Cleaning Specifications for
12 Appendix B
Series 500 Engines 108
12.1 Index 124
DCL-ID: 0000047995 - 009

4 | Table of Contents | A001072/06E 2022-03

 1 Preface
1.1 General information
These Fluids and Lubricants Specifications contain general instructions for the proper and safe operation of
your product from the manufacturer Rolls-Royce Solutions.

Used symbols and means of representation

The following instructions are highlighted in the text and must be observed:
Important
This field contains product information which is important or useful for the user. It refers to instructions,
work and activities that have to be observed to prevent damage or destruction to the material.

Note:
A note provides special instructions that must be observed when performing a task.

Fluids and lubricants

The service life, operational reliability and function of the drive systems are largely dependent on the fluids
and lubricants employed. The correct selection and treatment of these fluids and lubricants are therefore
extremely important. This publication specifies which fluids and lubricants are to be used.

mtu ValueCare Portfolio

With mtu ValueCare, Rolls-Royce Solutions offers approved oils and coolant tuned to the engine.
Test standard Designation
DIN Federal German Standards Institute
EN European Standards
ISO International Standards Organization
ASTM American Society for Testing and Materials
IP Institute of Petroleum
DVGW German Gas and Water Industry Association

Table 1: Test standards for fluids and lubricants

Important
Approved fluids and lubricants may not be mixed.

Important
TIM-ID: 0000051765 - 007

The customer must comply with the instructions specified in the safety data sheets of the respective manu-
facturers.

Applicability of this publication

The Fluids and Lubricants Specifications will be amended or supplemented as necessary. Prior to use, ensure
that the most recent version is available. The most recent version can be consulted under:
http://www.mtu-solutions.com
If you have any questions, your contact person will be happy to help you.

A001072/06E 2022-03 | Preface | 5

 Warranty
Use of the approved fluids and lubricants, either under the brand name or in accordance with the specifica-
tions given in this publication, constitutes part of the warranty conditions.
The supplier of the fluids and lubricants is responsible for the worldwide standard quality of the named prod-
ucts.
Important
Fluids and lubricants for drive systems may be hazardous materials. Certain regulations must be obeyed
when handling, storing and disposing of these substances.

These regulations are contained in the manufacturers' instructions, legal requirements and technical guide-
lines valid in the individual countries. Great differences can apply from country to country and a generally
valid guide to applicable regulations for fluids and lubricants is therefore not possible within this publication.
Users of the products named in these specifications are therefore obliged to inform themselves of the locally
valid regulations. Rolls-Royce Solutions accepts no liability whatsoever for improper or illegal use of the flu-
ids and lubricants which it has approved.
When handling fluids and lubricants the "Rules for the protection of the environment" (see Operating Instruc-
tions, Safety Regulations, Disassembly and Disposal) must be observed since they are hazardous to health
and flammable.
Incorrect use of fluids and lubricants causes environmental pollution:
• Fluids and lubricants must not enter the ground or the sewerage system.
• Used fluids and lubricants must be disposed of through used oil recycling or hazardous waste disposal.
• Used filter elements and cartridges must be disposed of with hazardous waste.
Important
The customer / operator bears the responsibility for observing the fuel values.

Preservation
All information on preservation, represervation and depreservation including the approved preservatives is
available in the Preservation and Represervation Specifications (publication number A001070/...). The most
recent version can be consulted under:
http://www.mtu-solutions.com

TIM-ID: 0000051765 - 007

6 | Preface | A001072/06E 2022-03

 2 Lubricants
2.1 General Information
2.1.1 Engine oil
The selection of a suitable engine oil for gas engines depends primarily on the type of gas used to power the
engine. The gas engine must only be operated with approved engine oil.
Approved engine oils are specified in the following chapters:
• For Series 4000 (→ Page 15)
• For Series 400 (→ Page 20)
• For Series 500 (→ Page 26)
An essential factor is the share of interfering contamination in the fuel gas. This requires that the operator
regularly carries out gas checks. The gas engine oils to be used are characterized by the lowest possible ash
content. This prevents increased ash deposits which can lead to reduced catalytic converter performance or
combustion knocking.
During operation with biogas, in certain circumstances the engine oil contains corrosive contaminants which
are created when the pollutants contained in the gas (chlorine, fluorine and sulfur compounds) are burned.
These corrosive constituents can only be neutralized to a limited extent even by special additives engine oil.
Corrosion damage to the oil-lubricated engine components can only be avoided by more frequent oil
changes. To improve buffering of concentration peaks when oil is subjected to corrosive contaminants, an
increased engine oil volume is urgently recommended.
Important
Dispose of used fluids and lubricants in accordance with local regulations.

Important
Viscosity grade SAE 40 is stipulated for gas engines.
Multigrade oils are not permitted.

Important
Mixing different engine oils is strictly prohibited.

Important
Changing to another oil grade can be accomplished in the course of an oil change provided certain condi-
tions are met. Contact the Service of Rolls-Royce Solutions.

Important
For applications with biogas, sewage gas or landfill gas, the quantity of oil in the engine oil pan is not ade-
quate. A larger volume of oil is required.
TIM-ID: 0000051962 - 007

A001072/06E 2022-03 | Lubricants | 7

 2.1.2 Engine oil limit values for Series 4000 and Series 400
Oil change intervals for gas engines
Engine oil change intervals depend on the engine-oil quality, its conditioning, the operating conditions and
the fuel used.
An oil sample must therefore be extracted on a regular basis depending on the engine oil volume, type of gas
and series and the oil analysis must be compared with the limit values from (→ Table 2). The oil samples
must always be taken under the same site conditions (engine at operation temperature) and at the designat-
ed point (extraction nozzle on oil filter housing).
If the limit values in accordance with (→ Table 2) are reached or exceeded, an oil change must be carried out
immediately.
When using an extended volume of oil, the limit values for wear elements must be reduced inversely propor-
tional to the volume enlargement. The maximum permissible reduction of limit values for the wear elements
is 50% of the limit value (→ Table 2).
Fixed oil change intervals without oil analysis are permitted following consultation with Rolls-Royce Solu-
tions.

Limit values for used gas engine oils SAE 40

Limit values for Series Limit values for Series
Test method 4000 400
Viscosity at 100 °C ASTM D445 Max. 17.5 New oil value +30 % **
(mm2/s) DIN 51562 Min. 11.5
Total base number TBN ASTM D2896 Min. 2.5 and TBN > TAN New oil value -60 % **
(mgKOH/g) ISO 3771
Total acid number, TAN ASTM D664 max. new oil value +2.5 On request from factory
(mgKOH/g)
iph value ASTM D7946 Min. 4 Min. 4
Water (% by vol.) ASTM D6304 Max. 0.2 Max. 0.2
EN 12937
ISO 6296
Glycol (mg/kg) ASTM D2982 Max. 100 On request from factory
Oxidation (A/cm) DIN 51453 Max. 20 Max. 30
Nitration (A/cm) DIN 51453 Max. 20 Max. 30
Wear elements (mg/kg): DIN 51399-1/-2
Iron (Fe) Max. 30 Max. 50
Lead (Pb) Max. 20 Max. 30
Aluminum (Al) Max. 10 Max. 20
Copper (Cu) Max. 20 *** Max. 50
Tin (Sn) Max. 5 Max. 15
TIM-ID: 0000051978 - 007

Silicon (Si) Max. 15 * Max. 10 *

* The limit value for the wear element Si only refers to natural gas operation.
** New oil value can be requested from the factory
*** During the 1st oil change (max. 3000 op. hrs.), the limit value is 50 ppm.
Table 2: Limit values for used gas engine oils SAE 40

Used-oil analysis
The results of the oil analyses must be archived.

8 | General Information | A001072/06E 2022-03

 From the indicated test methods and limit values, (→ Table 2) you can derive when the result of a single oil
sample analysis is to be viewed as abnormal. An abnormal result (e.g. increased wear of the oil) requires an
immediate investigation and rectification of the irregular operating condition (e.g. check of the gas prepara-
tion or analysis of the gas samples).
The limit values relate to individual oil samples. If the limit values are reached or exceeded, an oil change
must be carried out immediately. The results of the oil analysis do not necessarily indicate the wear taking
place on specific elements and components.
Aside from the analytical limit values, the condition, operating condition and possible malfunctions of the en-
gine and the periphery of the system are also of equal importance.
TIM-ID: 0000051978 - 007

A001072/06E 2022-03 | General Information | 9

 2.1.3 Engine oil limit values Series 500
Limit values for used gas engine oils
The following limit values must be observed when determining the oil change intervals for the corresponding
series and modules.
Important
With an installed lube oil volume extension, the following limit values for iron, lead, aluminum, tin, chromi-
um, copper and silicon must be halved in each case.
The reason for the limit value adaptation is the greater mixing of particles in the total oil filling volume.
Without an adaptation of the limit values the measures for damage prevention can not be introduced.

Test method Limit values Series

Characteristics 500
Viscosity at 100 °C (mm2/s) ASTM D445 Max. 17.5
DIN 51562
Total base number TBN (mgKOH/ g ASTM D2896 Min. 2.5
ISO 3771
Total acid number TAN (mgKOH/ g ASTM D664 Fresh oil valve +2.5
iph value ASTM D7946 Min. 4
Water (% by vol.) ASTM D6304 Max. 0.2
EN 12937
ISO 6296
Glycol (vol. %) ASTM D2982 Max. 0.02
DIN 51375
Oxidation (A/cm) DIN 51453 Max. 20
Nitration (A/cm) DIN 51453 Max. 20
Wear elements DIN 51399-1/-2
DIN 51396
Iron (Fe), ppm per 1000h Max. 20
Lead (Pb), ppm per 1000h Max. 35
Aluminum (Al), ppm per 1000h Max. 15
Copper (Cu), ppm per 1000h Max. 15
Tin (Sn), ppm per 1000h Max. 10
Silicon (Si), ppm Max. 15*
Chromium (Cr), ppm per 1000h Max. 5
Sodium (Na), ppm Max. 20
* For sewage gas applications, the limit value is increased to 100 mg/kg
Table 3: Limit values for used gas engine oils
TIM-ID: 0000092047 - 001

10 | General Information | A001072/06E 2022-03

 2.1.4 Silicon compounds in the fuel gas
Silicon compounds in the gas lead to deposits and promote wear. Even catalytic converters are deactivated
by these compounds. Damage caused by silicon compounds is not covered by the warranty.

Silicon operational value SiB

During operation with gases containing silicon, take particular note of the increased silicon content in the oil.
For this purpose, the silicon operational value SiB must be calculated with the help of the formula below.

(Oil fill quantity + top-up quantity) [liters]

SiB = Delta Si oil analysis B - A [ppm] x
generated electrical work [kWh]
Compliance with the SiB must be seamlessly verified by the operator's analyses.

Silicon operational value SiBG

With regard to the silicon operational limit values SiBG, a distinction is made between operating with a cata-
lytic converter and operating without one.
Operation SiBG
With catalytic exhaust gas cleaning 0
Without catalytic exhaust gas cleaning < 0.01 (Series 4000)
Without catalytic exhaust gas cleaning < 0.02 (Series 400)

Experience has shown that for the required use of oxidation catalytic converters, the impossibility of verifica-
tion must be requested (Si B = 0).
Nevertheless, due to the high sensitivity of the catalytic converter, premature activity loss can occur, particu-
larly at formaldehyde conversion.
Important
Rolls-Royce Solutions excludes damage caused by silicon to the engine and catalytic converter from the
warranty.

Example for calculating the silicon operating value SiB

Example data for calculating the silicon operating value SiB
Delta Si between oil analysis A and B 20 ppm (mg/kg)
Oil fill quantity in circulation 800 dm3
Topped up oil quantity 200 dm3
Generated electrical work between oil analysis A and B 2000000 kWh

(800 + 200) [dm3]

SIB = 20 [ppm] x =0.01
2000000 [kWh]
TIM-ID: 0000079056 - 004

A001072/06E 2022-03 | General Information | 11

 2.1.5 Fluorescent dyestuffs for detecting leaks in the lube oil circuit
The fluorescent dyestuffs listed below are approved for detection of leaks in the lube oil circuit.

Manufacturer Product name Working con- Material num- Container size Storage stabili-
centration ber ty)
Chromatech Eu- D51000A Chro- 0.04 % - 0.07 % X00067084 16 kg 2 years
rope B.V. matint
Fluorescent Yel-
low 175
Cimcool, Cincin- Producto 0,5 % - 1,0 % 5 gallons (canis- 6 months
nati YFD-100 ter)
55 gallons (bar-
rel)

Table 4:
1)
= ex works delivery, based on original and hermetically sealed containers in frost-free storage (> 5 °C).
The fluorescence (light-yellow color tone) of both dyestuffs is made visible with a UV lamp (365 nm).

TIM-ID: 0000055616 - 003

12 | General Information | A001072/06E 2022-03

 2.1.6 Lubricating greases
Requirements
The conditions for the approval of lubricating greases are specified in the delivery standard MTL 5050, which
can be ordered under this reference number.
Grease manufacturers are notified in writing if their product is approved.

Lubricating greases for general applications

Use lithium-saponified grease for all grease lubrication points.
Exceptions are:
• Compressor bypass, fitted between turbocharger and intercooler
• Coupling internal centering

Lubricating greases for applications at high temperatures

High-temperature grease (up to 250 °C) must be used for the compressor bypass installed between turbo-
charger and intercooler:
• Aero Shell Grease 15
• Optimol Inertox Medium
General purpose greases suffice for the compressor bypass located before the turbocharger or after the in-
tercooler.

Greases for internal centerings of couplings

Greases for internal centerings:
• Esso Unirex N 3 (temperature-stable up to approx. 160 °C)

Lubricants for special applications (only Series 4000)

Oil for turbochargers
Exhaust turbochargers with integrated oil supply are generally connected to the engine lube oil system.
For ABB turbochargers which are not connected to the engine lube oil system, mineral-based turbine oils
with viscosity grade ISO-VG 68 must be used.

Lubricating greases for curved tooth couplings

Depending on the application, the following lubricants have been approved for curved tooth couplings:
• Make: Klüber: Structovis BHD MF (highly-viscous lube oil)
• Make: Klüber: Klüberplex GE11–680 (adhesive gearbox/transmission lubricant)
Guidelines on use and service life are contained in the relevant Operating Instructions and Maintenance
Schedules.
TIM-ID: 0000079205 - 004

A001072/06E 2022-03 | General Information | 13

 2.1.7 Lubricating greases for general applications
For details and special features, see chapter "Lubricating greases"(→ Page 7)
Manufacturer Brand name Notes
Aral AG Mehrzweckfett Arallub HL2
BP p.l.c. Energrease LS2
Castrol Ltd. Spheerol AP2
Chevron Multifak EP2
SRS Schmierstoff Vertrieb GmbH SRS Wiolub LFK2
Shell Deutschland GmbH Shell Gadus S2 V220 2
Total Total Multis EP2
Veedol International Multipurpose

Table 5:

TIM-ID: 0000019094 - 004

14 | General Information | A001072/06E 2022-03

 2.2 Series 4000 gas engine – Generator application and engine-
generator set - marine application
2.2.1 Approved engine oils
For details and special features, see chapter "General" (→ Page 7).

mtu ValueCare engine oils for Series 4000 gas engines

Manufacturer Product/Brand Model type Comments /
name material num-

4000L32 / L33 / L32FNER

ber

4000L61 / L62 / L63

4000L64 / L64FNER
SAE viscosity class

4000L62FB*

4000Mx5xN
4000L32FB
Rolls-Royce Solutions GEO BG Power 40 X X 20 l container:
GmbH B2L X00072870
205 l contain-
er:
X00072871
IBC:
X00072872
Tank:
X00073862
GEO NG Power 40 X 20 l container:
X2L X00072874
205 l contain-
er:
X00072875
IBC:
X00072876
Tank:
X00073865
GEO NG Power 40 X X X X 20 l container:
X3L X00072877
205 l contain-
er:
X00072878
IBC:
X00072879
TIM-ID: 0000077948 - 007

Tank:
X00073866
X = Approval for model type
* = With this model type, the additional information in the Technical Description under the item
Lube oil system must be observed when selecting the approved engine oil.
Table 6: Engine oils for Series 4000 gas engines
Important
To determine the engine oil change intervals, oil samples must be taken every 250 op. hrs. and analyzed.
The limit values must be observed (→ Page 8).

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 15
 Alternative engine oils for Series 4000 gas engines
Manufacturer Brand name Model type

4000L32 / L33 / L32FNER

4000L61 / L62 / L63

4000L64 / L64FNER
SAE viscosity class

4000L62FB**

4000Mx5xN
4000L32FB
Addinol MG 40 Extra LA 40 X X
MG 40 Extra Plus 40 X
BayWa AG Tectrol MethaFlexx HC Pre- 40 X X
mium
Castrol Ltd. Castrol Duratec L 40 X X*
Exxon Mobil Corporation Mobil Pegasus 705 40 X X*
Mobil Pegasus 805 (55 gal- 40 X X*
lons: 23538056)
Mobil Pegasus 1005 40 X X X
(55 gallon drum: 800019)
Fuchs Europe Schmierstoffe Titan Ganymet Ultra 40 X X
GmbH Titan Ganymet LA 40 X
NILS S.p.A. Burian 40 X
Schnell Motoren GmbH Schnell Protect Oil 40 X X
Shell International Petrole- Shell Mysella S3 N 40 40 X X*
um Company Shell Mysella S5 N 40 40 X X X
SRS Schmierstoff Vertrieb SRS Mihagrun LA 40 40 X X*
GmbH
Total Deutschland Nateria MH40 40 X X*
Nateria MJ40 40 X
Nateria MP40 40 X X X X X X
Petro-Canada Europe Lubri- Sentron CG 40 (205 l drum: 40 X X
cants Ltd. 800262)
Sentron LD 5000 40 X
Sentron LD 8000 (205 l 40 X X X X
drum: 800315)
X = Approval for model type
TIM-ID: 0000077948 - 007

* The use of these engine oils shortens the service life.

** = With this model type, the additional information in the Technical Description under the item
Lube oil system must be observed when selecting the approved engine oil.
Table 7: Alternative engine oils for Series 4000 gas engines

16 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Important
With engine operation only with oil pan and automatic refilling, an oil sample must be extracted every 250
op. hrs.
With engine operation (8V and 12V) with extended circulation volume, with oil volumes > 1000 l, the oil
samples can be extracted every 500 op. hrs.
With engine operation (16V and 20V) with extended circulation volume, with oil volumes > 2000 l, the oil
samples can be extracted every 500 op. hrs.
From a run time of 3000 op. hrs. onwards, or if the limit values are being approached, the sampling interval
must be reduced to 250 op. hrs.
The limit values must be observed (→ Page 8).
TIM-ID: 0000077948 - 007

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 17
 2.2.2 Lubricating greases for generators
The generator manufacturers lubricate the bearings before shipment.
Lubricant must be added when the unit is out into operation.
Important
The specifications on the generator plate are always applicable.
Observe the manufacturer's specifications on the generator nameplate.

The manufacturers provide the following information on the generator:

• Lubricating grease to be used
• Amount of grease to be added
• Lubricating interval
The applicable Maintenance Schedule must be complied with.
Further information is available in the manufacturer's documentation.
Important
The temperature of the generator bearings should be monitored during the first operating hours.

Important
Poor lubrication can lead to excessive temperatures and damage to the bearings.

Lubricating greases for generators with Series 4000 gas engines

Generator manufacturer Lubricating grease (mtu material number)
Leroy-Somer Shell Gadus S3 V220C2 (X00067217) *
Mobil Polyrex™ EM: grade NLGI 2 (X00071899) *
Cummins KLUEBER ASONIC GHY72 (09110145007)
Hitzinger LUKOIL SIGNUM EPX2 (X00071900)
* According to the manufacturer, operation with a mixture of the two lubricating greases is not per-
mitted. Observe the manufacturer's specifications on the generator nameplate.

TIM-ID: 0000072708 - 004

18 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 2.2.3 Gear oils
Approved lubricating oils
Only applies for 60 Hz applications.
Manufacturer / supplier Designation SAE Viscosity class Note
Mobil Mobilgear SHC XMP320 (5 gallons: 40 S
800233 / (55 gallons: 800232)
Mobil SHC 632 (5 gallons: 800235 / (55 gallons: 40 S
800234)
Klüber GEM4-320N 40 S
Total Carter SH320 40 S
S = synthetic lube oil
Table 8: Approved lubricating oils
Important
Only synthetic gear oil types are permitted.

Capacity
Type of gearbox/transmission Engine liter
GU 320 8V4000Lx 65
12V4000Lx
GU 395 16V4000Lx 92
20V4000Lx

Table 9: Capacity
The test run is carried out at Rolls-Royce Solutions with Mobil SHC 632.
mtu material number:
• 09110149525 – gear oil MOBIL SHC 632 (barrel)
• 09110149555 – gear oil MOBIL SHC 632 (canister)
Oil change intervals:
• Also refer to the Maintenance Schedule from Rolls-Royce Solutions and the operating instructions of the
gearbox manufacturer
• First oil change after 500 operating hours, then every 6000 operating hours
• Regular oil analysis in accordance with the Maintenance Schedule
Fill cold gear oil exactly up to the middle of the sight glass. During operation, the oil level at the sight glass
initially sinks but can subsequently rise above it due to temperature expansion. Ventilation takes place via
the labyrinth seal at the shafts.
TIM-ID: 0000051979 - 006

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 19
 2.3 Series 400 gas engine – Engine-generator set
2.3.1 Approved engine oils
mtu ValueCare engine oils for naturally-aspirated Series 400 engines
Manufacturer/Supplier Product/Brand name SAE viscosity Note
class
Rolls-Royce Solutions GmbH GEO NG POWER X2L 2) 401) M E, P
GEO NG POWER X3L 3) 401) M E. P

Table 10: Engine oils for naturally-aspirated Series 400 engines

1) Approval conditional on ambient temperature at engine being > +10 °C
2) 20 l container: X00072874 / 205 l container: X00072875 / IBC: X00072876 / Tank: X00073865
3) 20 l container: X00072877 / 205 l container: X00072878 / IBC: X00072879 / Tank: X00073866
M Mineral engine oil
E Natural gas
P Propane

Alternative engine oils for naturally-aspirated Series 400 engines

Manufacturer/Supplier Brand name SAE viscosity Note
class
Addinol Lube Oil GmbH ECO GAS 4000 XD 401) M E, P
MG 40 Extra LA 401) M E, P
AVIA AG LA 40 40 1) M E, P
LA Plus 40 401) M E, P
Castrol Duratec XPL 401) S E, P
Chevron Texaco HDAX 7200 401) M E, P
C+M GmbH C+M Sevelub E9038-04 401) S E, P
BayWa AG TECTROL Methaflexx HC Premium 40 1) M E, P
TECTROL Methaflexx NG 401) M E, P
Eni Schmiertechnik GmbH Eni Geum 40 401) M E, P
ExxonMobil SHC Pegasus 40 40 1) S E, P
Pegasus 605 401) M E, P
Pegasus 705 40 1) M E, P
Pegasus 805 401) M E, P
Pegasus 1005 401) M E, P
TIM-ID: 0000053541 - 009

Pegasus 1107 40 1) M E, P
Fuchs Europe Schmierstoffe Titan Ganymet LA 401) M E, P
GmbH
Titan Ganymet Ultra 40 1) M E, P
Kuwait Petroleum Q8 Mahler MA 401) M E, P
Petro-Canada Europe Lubri- Sentron LD 5000 401) M E, P
cants Ltd.
Sentron LD 8000 40 1) M E, P

20 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 Manufacturer/Supplier Brand name SAE viscosity Note
class
Shell International Petroleum Shell Mysella S5 N 40 401) M E, P
Company
Shell Mysella S5 S 40 401) M E, P
Total Deutschland Total Nateria MP40 401) M E, P

Table 11: Alternative engine oils for naturally-aspirated Series 400 engines
1) Approval conditional on ambient temperature at engine being > +10 °C
S Synthetic engine oil
M Mineral engine oil
E Natural gas
P Propane

mtu ValueCare engine oils for Series 400 turbo engines

Manufacturer/Supplier Product/Brand name SAE viscosity Note
class
Rolls-Royce Solutions GmbH GEO BG POWER B2L 2) 40 1) M B K
GEO NG POWER X2L 3) 40 1) M E, P K
GEO NG POWER X3L 4) 40 1) M E, P K

Table 12: Engine oils for Series 400 turbo engines

1) Approval conditional on ambient temperature at engine being > +10 °C
2) 20 l container: X00072870 / 205 l container: X00072871 / IBC: X00072872 / Tank: X00073862
3) 20 l container: X00072874 / 205 l container: X00072875 / IBC: X00072876 / Tank: X00073865
4) 20 l container: X00072877 / 205 l container: X00072878 / IBC: X00072879 / Tank: X00073866
M Mineral engine oil
E Natural gas
P Propane
B Biogas
K suitable for catalytic converter

Alternative engine oils for Series 400 turbo engines

Manufacturer/Supplier Brand name SAE viscosity Note
class
AVIA AG HA 40 40 1) M B K
LA 40 40 1) M E, P K
LA Plus 40 40 1) M E, P K
Addinol Lube Oil GmbH ECO GAS 4000 XD 40 1) M E, P K
MG 40 Extra Plus 40 1) M B K
MG 40 Extra LA 40 1) M E, P K
TIM-ID: 0000053541 - 009

BayWA AG TECTROL Methaflexx D 40 1) M B K

TECTROL Methaflexx GE-M 40 1) M B K
TECTROL Methaflexx HC Plus 40 1) M B K
TECTROL Methaflexx HC Premium 40 1) M E, P K
TECTROL Methaflexx HC Premium 40 1) M B SRK
TECTROL Methaflexx NG 40 1) M E, P K
Castrol Duratec XPL 40 1) S E, P K

A001072/06E 2022-03 | Series 400 gas engine – Engine-generator set | 21

 Manufacturer/Supplier Brand name SAE viscosity Note
class
Chevron Texaco HDAX 7200 40 1) M E, P K
Eni Schmiertechnik GmbH Eni Geum 40 401) M E, P K
ExxonMobil SHC Pegasus 40 40 1) S E, P K
Pegasus 605 40 1) M E, P K
Pegasus 605 Ultra 40 1) M B SCR
Pegasus 610 40 1) M B K
Pegasus 705 40 1) M E, P K
Pegasus 710 40 1) M B K
Pegasus 805 40 1) M E, P K
Pegasus 1107 40 1) M E, P K;
Fuchs Europe Schmierstoffe Titan Ganymet 40 1) M B K
GmbH
Titan Ganymet LA 40 1) M E, P K
Titan Ganymet Plus 40 1) M B K
Titan Ganymet Ultra 40 1) M E, P K
Titan Ganymet Ultra 40 1) M B SRK
Hessol Lubrication GmbH Hessol Gasmotorenöl 40 1) M B K
Kuwait Petroleum Q8 Mahler HA 40 1) M B K
Q8 Mahler MA 40 1) M E, P K
NILS Burian 40 1) M B K
Petro-Canada Europe Lubri- Sentron CG 40 40 1) M B K
cants Ltd.
Sentron LD 5000 40 1) M E, P K
Sentron LD 8000 40 1) M E, P K
Shell International Petroleum Shell Mysella S5 N 40 40 1) M E, P K
Company
Shell Mysella S5 S 40 40 1) M E, P, SCR
B
Total Deutschland Total Nateria MJ40 401) M B K
Total Nateria MP40 40 1) M E, P K

Table 13: Alternative engine oils for Series 400 turbo engines
1) Approval conditional on ambient temperature at engine being > +10 °C
S Synthetic engine oil
M Mineral engine oil
E Natural gas
TIM-ID: 0000053541 - 009

P Propane
B Biogas
K suitable for catalytic converter
SRK Sulfur-resistant catalytic converter
SCR Selective catalytic reduction catalytic converter

22 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 2.3.2 Engine oil change intervals
Mineral oil, engine oil system with oil bleed system and additional capacity
If the additional capacity is increased, e.g. to 800 l for the E3066Dx, the oil change interval will also increase
4-fold in comparison to the case where the additional capacity is 200 l.
Oil analyses need to be carried out at regular intervals in such cases.
With an increase in the oil volume, the change intervals of the oil filters in acc. with the service plan still
apply.
Designation Engine oil system with oil bleed system and additional capacity
Module / engine-generator set Oil change based on operating Min. additional capacity
with engine model hours
E3066D1-D3 2500 200 l
E3066D4 3000 200 l
E3066Lx/Zx 1000 120 l
E3042D1-D3 1250 200 l
E3042D4 1500 200 l
E3042Lx/Zx 1000 200 l
E3042Lx/Zx 5000 (or oil analysis) 1000 l
B3066Lx/Zx 1000 200 l
B3042Lx/Zx 1000 300 l

Table 14: Mineral oil, engine oil system with oil bleed system and additional capacity

Mineral oil, engine oil system with fresh-oil replenishment function only (no
oil bleed system)
Designation Engine oil system with fresh-oil replenishment function only (no
oil bleed system)
Module / engine-generator set Oil change based on operating Recommended capacity of fresh-
with engine model hours oil tank
E3066D1-D3 600 60 l
E3066Lx/Zx 300 60 l
E3042D1-D3 600 60 l
E3042Lx/Zx 300 60 l

Table 15: Mineral oil, engine oil system with fresh-oil replenishment function only (no oil bleed system)

Synthetic oil, engine oil system with oil bleed system and additional capacity
If the additional capacity is increased, e.g. to 800 l for the E3066Dx, the oil change interval will also increase
TIM-ID: 0000053502 - 003

4-fold in comparison to the case where the additional capacity is 200 l.

Oil analyses need to be carried out at regular intervals in such cases.
With an increase in the oil volume, the change intervals of the oil filters in acc. with the service plan still
apply.

A001072/06E 2022-03 | Series 400 gas engine – Engine-generator set | 23

 Designation Engine oil system with oil bleed system and additional capacity
Module / engine-generator set Oil change based on operating Min. additional capacity
with engine model hours
E3066Lx/Zx 2000 200 l
E3042Lx/Zx 1000 160 l
E3042Lx/Zx 8000 (or oil analysis) 1000 l

Table 16: Synthetic oil, engine oil system with oil bleed system and additional capacity

Synthetic oil, engine oil system with fresh-oil replenishment function only (no
oil bleed system)
Designation Engine oil system with fresh-oil replenishment function only (no
oil bleed system)
Module / engine-generator set Oil change based on operating Recommended capacity of fresh-
with engine model hours oil tank
E3066D1-D3 1250 50 l
E3066D4 1500 50 l
E3066Lx/Zx 600 50 l
E3042D1-D3 1250 100 l
E3042D4 1500 100 l
E3042Lx/Zx 600 100 l

Table 17: Synthetic oil, engine oil system with fresh-oil replenishment function only (no oil bleed system)

TIM-ID: 0000053502 - 003

24 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 2.3.3 Lubricating greases for generators
Lubricating greases for generators in Series 400
Generator manufacturer Lubricating grease
Leroy-Somer Lubricated for life

Important information
Observe the manufacturer's specifications on the generator nameplate.
TIM-ID: 0000072692 - 002

A001072/06E 2022-03 | Series 400 gas engine – Engine-generator set | 25

 2.4 Series 500 Gas Engine - Engine-Generator Set
2.4.1 Approved engine oils
Special gas engine oils must be used for the gas engines and be evaluated according to described criteria.
Approved products for all series including the corresponding sample sets can be obtained directly from Rolls-
Royce Solutions.
Important
The use of oil additives is prohibited.

If pollutant values that negatively influence the oil level are exceeded (in particular, hydrogen sulfide (H2S)),
the oil change intervals must be shortened following consultation with Rolls-Royce Solutions.

Manufacturer/Supplier Brand name

Shell Mysella S5 S40
Mobil Pegasus 1005
Addinol Eco Gas 4000 XD

Table 18: Approved oils for natural gas (biogas, sewage gas)

The oil volume is composed as follows:

Engine Engine oil pan Auxiliary tank in the base frame (op- Total
tion)
12V500 90 l 190 l 280 l
8V500 60 l 140 l 200 l
6R500 40 l 100 l 140 l

Table 19: Composition of the oil volume

TIM-ID: 0000091952 - 003

26 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 2.4.2 Engine oil change intervals
The engine oil service lives must be determined based on regular oil analyses depending on the operating
conditions.
The oil change must always be carried out depending on the engine oil condition.

Oil sample intervals

During the first oil interval, sample intervals of 250 op. hrs. starting after 250 op. hrs. must be observed.
After the third sample extraction, i.e. after 750 op. hrs., an oil change must be carried out in all circumstan-
ces.
Based on the last sample, a service life forecast can be made for the next oil interval. With the first three oil
fillings of an engine, Rolls-Royce Solutions recommends to always start sampling at the latest at 500 op. hrs.
with sampling in a 250 op. hrs. cycle because considerable changes in the oil load are still possible in the
running-in phase of an engine.
Important
Rolls-Royce Solutions recommends continuous monitoring of the gas quality. The sampling intervals can
only be guaranteed if the required gas quality is observed and fluctuations are low. Insufficient monitoring
of the gas quality makes shorter oil sampling intervals necessary.
The oil change must be carried out based on the condition. The operating company must ensure that the
trend resulting from the analyses does not result in the named limit values being exceeded (→ Page 10).
With the use of biogas in particular, it is recommended to observe a buffer between the maximum oil limit
values. Rolls-Royce Solutions recommends an oil change when 80% of the wear values have been reached.
After major repair measures (e.g. after an inspection) or after changing the oil grade, the procedure for de-
termining the oil change intervals in accordance with the above instructions must be carried out again.

For each engine of a plant, after testing the plant-specific oil service life every additional oil filling must also
be analyzed again. For the further analytical operational monitoring or low-risk maximization of the oil usage
time,
• at approx. 60%,
• at approx. 80% and
• at approx. 100%
of the tested or statistically evaluated oil service life, used oil analyses are prescribed.
Independently of the oil change interval, you must always ensure that the oil analysis interval does not ex-
ceed 500 op. hrs. With a biogas application with seriously fluctuating fuel gas quality, a considerably reduced
maximum oil analysis interval of 100 operating hours can be expected.
Before carrying out an oil change, a sample must be taken and sent for analysis.

Biogas operation
In biogas operation, it can be anticipated that a reduction in the oil service life is necessary depending on the
given fuel gas quality.
A reduction in the oil change intervals is necessary if a constant gas quality can not be guaranteed or if the
gas quality is subject to major fluctuations (e.g. with the use of syngases).
TIM-ID: 0000091954 - 003

Oil filter
The oil filter(s) must be replaced during every oil change.
In the case of long oil service lives (> 1000 h) or with a low annual utilization of the engine, the oil filter must
be replaced at least once a year independently of the oil change or be replaced during all scheduled mainte-
nance.

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 27

 2.4.3 Oil volume
Oil volume extension and line systems
If the resultant oil service life is not fully satisfactory, by increasing the engine oil capacity with the option
"Oil volume extension" the oil service life can be extended.

Procedure to change to a different oil grade

To keep the described influences to a minimum, Rolls-Royce Solutions recommends the following oil change-
over procedure:
1. Drain the oil of the original brand as completely as possible.
2. Fill the new oil grade up to the minimum marking of the engine.
3. Run the engine for 2 hours at full load.
4. Carry out an oil and filter change.
The achievable oil service life must be checked again using the described procedure, see (→ Page 27).
Important
The oil supply tank and all lines must be flushed accordingly with the new oil in order to keep the influences
here also to a minimum.

TIM-ID: 0000091955 - 002

28 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 2.4.4 Lubricating greases for generators
Lubricating greases for generators in Series 500
Generator Lubricating grease
LSAH 44.3 Esso Unirex N3
LSA 49.1 / 49.3 optional LSA
46.3 / 46.1 / 47.2

Important
Observe the manufacturer's specifications on the generator nameplate.
TIM-ID: 0000094907 - 001

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 29

 3 Coolants
3.1 General Information
3.1.1 Coolant – Definition
Important
Ensure that used fluids and lubricants are collected in sufficiently large collecting containers. Observe safe-
ty data sheets and dispose of used fluids and lubricants in accordance with country-specific regulations.

Coolant = coolant additive (concentrate) + fresh water to predefined mixing ratio

• Ready for use in engine

Antifreeze = Corrosion inhibitor + glycol + additives + water

• The predecessor version of the Fluids and Lubricants Specifications
used the term "corrosion inhibiting antifreeze". For clarity purposes,
this publication uses the term "Antifreeze".
Antifreeze is necessary for engine operation in areas where below-freezing temperatures may occur.
The relevant concentration range for use is listed in the section on operational monitoring.
Coolant without antifreeze = Corrosion inhibitor + additives + water
• The predecessor version of the Fluids and Lubricants Specifications
used the term "water-soluble corrosion inhibitors". This designation
will be replaced with immediate effect with "coolant without anti-
freeze".
The coolants approved by Rolls-Royce Solutions ensure adequate corrosion protection provided the correct
concentrations are used. The relevant concentration range for use is listed in the section on operational
monitoring.
Approved coolant additives are specified in the following chapters:
• For Series 4000 gas engine – marine application (→ Page 44)
• For Series 4000 gas engine – generator application and engine-generator set(→ Page 54)
• For Series 4000 gas engine – engine-generator set (→ Page 64)
• For Series 500 gas engine – engine-generator set (→ Page 67)
.
Special arrangements presently in effect remain valid.
Important
Coolant additives containing nitrite must not be used in conjunction with coolers that contain brass.

Important
Flushing with water is required at every change to a different coolant product. For flushing and cleaning
specifications for engine coolant circuits, see (→ Page 102).
TIM-ID: 0000051961 - 008

Note
• The product BASF Glysantin® G30®pink is available for use at extremely low temperatures (-60 °C/arctic
regions).
The corrosion-inhibiting effect of coolant is only ensured with the coolant circuit fully filled.
Only corrosion inhibitors approved for internal preservation of the coolant circuit also provide proper corro-
sion protection when the medium is drained. This means that, after draining of the coolant, the cooling cir-
cuit must be preserved if the coolant is not refilled. The procedure is described in the Preservation and Rep-
reservation Specifications A001070/...

30 | Coolants | A001072/06E 2022-03

 Coolants must be prepared from suitable fresh water and a coolant additive approved by Rolls-Royce Solu-
tions. Conditioning of the coolant must take place outside the engine.
Important
Mixtures of different coolant additives and supplementary additives (also in coolant filters and filters down-
stream of plant components) are not permitted.

Important
For ready mixtures, the proportion of coolant additive (concentrate) is always named first.
Example: Coolant AH 40/60 Antifreeze Premix = 40% by volume Coolant additive / 60% by volume Fresh-
water
TIM-ID: 0000051961 - 008

A001072/06E 2022-03 | General Information | 31

 3.1.2 Operational monitoring / coolant conditioning for Series 4000 and 400 engines
Inspection of the freshwater and continuous monitoring of the coolant are essential for trouble-free engine
operation. Fresh water and coolant should be checked at least once per year and with each fill-up. Inspec-
tions can be carried out using the mtu test kit, or by an authorized laboratory. The mtu test kit contains the
necessary equipment, chemicals and instructions for use.
Analysis Method for on-site checks Method for lab analysis
(mtu test kit)
Determination of the water hard- Titration Determination of the Ca and Mg
ness content by means of ICP and cal-
culation of the hardness in °dH or
mmol/l
Determination of the pH value Litmus paper strips for an appro- ASTM D 1287
priate measuring range
Determination of the chloride con- Titration IC
tent
Determination of the sulfate con- - IC
tent
Determination of the silicon con- - ICP
tent
Determination of additive concen- Brix refractometer, compare de- Refractometer method DIN
tration in aqueous coolant solu- gree(s) Brix against table 51423, compare Brix degree
tions (→ Table 22) and read off concen- against table (→ Table 22) and
tration in % by volume read off concentration in % by vol-
ume
Determination of antifreeze con- Glycol refractometer, concentra- Refractometer method DIN
centration tion in % by volume can be read 51423, calculation through refrac-
off directly tion index or product-specific fac-
tor
Determination of germ total for - Dip slides (tube with culture medi-
aqueous media um, e.g. by VWR Prolabo No.
535112D or equivalent) incuba-
tion time: 4 days at 30 °C

Table 20: Minimum requirements and methodology for coolant monitoring

Orders for freshwater and coolant analysis may be placed with Rolls-Royce Solutions. In particular cases, op-
erational monitoring can cover more checks that those listed in table (→ Table 20). Please contact your part-
ner if necessary.

Permissible concentrations of antifreezes

Minimum Maximum
Antifreeze on ethylene glycol basis 35% by vol- 40% by vol- 45% by vol- 50% by vol-
TIM-ID: 0000078628 - 006

ume ume ume ume

With antifreeze protection up to* -20 °C -25 °C -31 °C -37 °C
BASF Glysantin® G30® pink 65% by volume for application at outside temperatures
of up to -60 °C in arctic regions
* = antifreeze specifications determined as per ASTM D 1177
Table 21: Permissible concentrations of antifreezes
Important
After flushing the engine coolant circuit, the concentration of antifreeze must not exceed 35% by volume.

32 | General Information | A001072/06E 2022-03

 Add antifreeze to the fresh water with a concentration of at least 35% by volume when antifreeze protection
to minus - 20 °C is sufficient. If lower ambient temperatures are expected, the concentration must be in-
creased accordingly. A concentration of above 50% by volume is impermissible.
Mixtures containing a proportion of antifreeze below 35% by volume do not guarantee adequate corrosion
protection.
Use the treated water in both summer and winter operation. Compensate for coolant losses in such a way as
to maintain the antifreeze concentration.

Permissible concentrations, coolant without antifreeze for all applications

Permis- Manufacturer Reading on hand refractometer) at 20 °C (= de-
sible grees Brix)
concen- Product/Brand name % by vol.
tration
range 7 8 9 10 11 12
9 to 11% Rolls-Royce Sol- Coolant CS 100 Corro-
by vol- utions GmbH sion Inhibitor Concen- 3.5 4.0 4.5 5.0 5.5 6.0
ume trate
Coolant CS 10/90 Cor-
3.5 4.0 4.5 5.0 5.5 6.0
rosion Inhibitor Premix
Rolls-Royce Sol- Power Cool® Plus 6000
utions America 3.5 4.0 4.5 5.0 5.5 6.0
Inc.
Arteco Freecor NBI Please use test kit of manufacturer
BASF SE Glysacorr G93 green 3.5 4.0 4.5 5.0 5.5 6.0
CCI Corporation A 216 4.9 5.6 6.3 7.0 7.7 8.4
CCI Manufac- A 216
turing IL Corpo- 4.9 5.6 6.3 7.0 7.7 8.4
ration
Chevron Texcool A -200 Please use test kit of manufacturer
Detroit Diesel Power Cool Plus 6000
4.9 5.6 6.3 7.0 7.7 8.4
Corporation
Drew Marine Drewgard XTA 3.5 4.0 4.5 5.0 5.5 6.0
ExxonMobil Mobil Delvac Extended
4.9 5.6 6.3 7.0 7.7 8.4
Life Corrosion Inhibitor
Ginouves York 719 3.5 4.0 4.5 5.0 5.5 6.0
Old World In- Final Charge Extended
dustries Inc. Life Corrosion Inhibitor 4.9 5.6 6.3 7.0 7.7 8.4
(A 216)
Valvoline OEM Advanced 93 3.5 4.0 4.5 5.0 5.5 6.0
Zerex G-93 3.5 4.0 4.5 5.0 5.5 6.0
TIM-ID: 0000078628 - 006

1)
= concentration determination by means of suitable hand refractometer
Table 22: Permissible concentrations, coolant without antifreeze for all applications
Calibrate the hand refractometer with clean water at coolant temperature. The coolant temperature should
be 20 °C. Observe the specifications of the manufacturer.
Important
After flushing the engine coolant circuit, the concentration of corrosion inhibitor must not exceed 9% by
volume.

A001072/06E 2022-03 | General Information | 33

 Permissible concentrations, additional coolant without antifreeze exclusively for
marine (free of light metals)
Permis- Reading on hand refractometer) at 20 °C (= de-
sible grees Brix)
concen- Manufacturer Brand name % by vol.
tration
range 7 8 9 10 11 12
7 to 11% Arteco Havoline Extended Life
by vol- Corrosion Inhibitor XLI 2.6 3.0 3.4 3.7 4.1 4.4
ume [EU 32765]
Chevron Lubri- Delo XLI Corrosion Inhib-
2.6 3.0 3.4 3.7 4.1 4.4
cants itor - Concentrate
Nalco Water An Alfloc™ 3443 1.75 2.0 2.25 2.5 2.75 3.0
Ecolab Compa- Alfloc™ 3477
ny 1.75 2.0 2.25 2.5 2.75 3.0

Chiron Chemi- PrixMax RCP

2.6 3.0 3.4 3.7 4.1 4.4
cals Pty Ltd
Total WT Supra 2.6 3.0 3.4 3.7 4.1 4.4
5 to 6% Fleetguard DCA-4L
by vol- Please use test kit of manufacturer
ume
3 to 4% Detroit Diesel Power Cool 2000
by vol- Corporation
ume Nalco Water An Nalcool® 2000
Please use test kit of manufacturer
Ecolab Compa-
ny
Penray Pencool 2000
1)
= concentration determination by means of suitable hand refractometer
Table 23: Permissible concentrations, additional coolant without antifreeze exclusively for marine (free of light
metals)
Calibrate the hand refractometer with clean water at coolant temperature. The coolant temperature should
be 20 °C. Observe the specifications of the manufacturer.

Permissible concentrations, antifreeze on ethylene glycol basis

The concentration is determined using a suitable glycol refractometer and direct reading of the scale value in
% by vol.

Limit values for coolants

pH value when using:
– Antifreeze Min. 7.5 Max. 9.0
TIM-ID: 0000078628 - 006

– Coolant without antifreeze for engines containing light metal Min. 7.5 Max. 9.0
– Coolant without antifreeze for engines free of light metal Min. 7.5 Max. 11.0
– Silicon (valid for coolants containing Si) Min. 25 mg/l

34 | General Information | A001072/06E 2022-03

 Important
For a holistic appraisal of a coolant function, apart from the above-mentioned limit values the respective
coolant-specific characteristic data and the fresh water quality used must be taken into consideration (lab
examination).
The check of the current pH value must be carried out together with the check of the antifreeze concentra-
tion, however, at least every 3000 op. hrs. For a rapid on-site examination, pH indicator strips are suitable
(recommend measuring range 6.5 to 10.0). The results must be documented.
TIM-ID: 0000078628 - 006

A001072/06E 2022-03 | General Information | 35

 3.1.3 Coolant concentrates – Storage capability
The storage capability specifications refer to coolant concentrates in original, hermetically sealed packing
with storage temperatures up to max. 30 °C.
Follow manufacturer's instructions.
Limit val-
Coolant concentrate ue Brand name / Comments
Antifreeze Approx. 3 Observe manufacturer's specifications
years
Coolant without antifreeze 2 years Arteco Freecor NBI
Chevron Texcool A-200
Detroit Diesel Corp. Power Cool 2000
ImproChem Cool-C18
Nalco Nalcool® 2000
Penray Pencool 2000
PrixMax RCP
3 years BASF Glysacorr G93 green
Drew Marine Drewgard XTA
Ginouves York 719
Rolls-Royce Solutions Coolant CS100
Rolls-Royce Solutions America inc. Power Cool® Plus 6000
Nalco Alfloc™ 3477
Valvoline OEM Advanced 93
Valvoline ZEREX G-93
5 years Arteco Havoline Extended Life Corrosion Inhibitor XLI [EU
032765]
CCI Corporation A216
CCI Manufacturing IL A216
Chevron Delo XLI Corrosion Inhibitor Concentrate
Detroit Diesel Corp. Power Cool Plus 6000
ExxonMobil Mobil Delvac Extended Life Corrosion Inhibitor
Fleetguard DCA-4L
Old World Industries Final Charge Extended Life Corrosion
Inhibitor (A216)
Total WT Supra

Table 24: Coolant concentrates – Storage capability

Note
• For reasons of corrosion protection, do not store in galvanized containers. Take this requirement into ac-
count when coolant must be transferred.
• Containers must be hermetically sealed and stored in a cool, dry place. Frost protection must be provided
in winter.
• Further information can be obtained from the product and safety data sheets for the individual coolants.
TIM-ID: 0000078631 - 005

36 | General Information | A001072/06E 2022-03

 3.1.4 Color additives to detect leakage in the coolant circuit
The fluorescent dye listed below is approved as an additive for coolant without antifreeze and antifreeze to
detect leakages.
1)
= Based on original and hermetically sealed containers in frost-free storage (> 5 °C)

Approved color additives

Manufacturer Product name Material no. Container size Storage stability)
Chromatech Inc. D11014 Chromatint X00066947 20 kg 2 years
Chromatech Europe Uranine Conc
B.V.

Table 25:

Application:
Add approx. 40 g of dye per 180 l of coolant.
This is a generous amount of dye which is not to be exceeded.

Fluorescence (yellow hue) is clearly visible in daylight. UV light with a wavelength of 365 nm can be used in
darker rooms.
TIM-ID: 0000053354 - 005

A001072/06E 2022-03 | General Information | 37

 3.1.5 Preventing damage to cooling system
• When topping up (following loss of coolant), ensure that not only water but also concentrate is added. The
specified antifreeze and/or corrosion inhibitor concentration must be maintained.
• Do not exceed an antifreeze concentration of 50% by volume Use antifreeze. Concentrations in excess of
this reduce antifreeze protection and heat dissipation. Only exception: BASF Glysantin® G30® pink (spe-
cial application)
• The coolant must not contain any oil or copper residue (in solid or dissolved form).
• The majority of corrosion inhibitors currently approved for internal coolant circuit preservation are water-
soluble and do not provide antifreeze protection. Make sure that the engine is stored safe from frost, be-
cause a certain amount of coolant remains in the engine after draining.
• A coolant circuit can usually not be drained completely, i.e. residual quantities of used coolant or freshwa-
ter from a flushing procedure remain in the engine. These residual quantities can result in the dilution of a
coolant to be filled (mixed from a concentrate or use of a ready mixture). This dilution effect is higher the
more add-on components there are on the engine. Check the coolant concentration in the coolant circuit
and adapt it if necessary.
Important
All coolants approved in these Fluids and Lubricants Specifications generally relate only to the coolant cir-
cuits of mtu engines / systems. In the case of complete propulsion plants, the fluids and lubricants appro-
vals of the component manufacturer must be observed.

Important
For corrosion-related reasons, it is not permissible to operate an engine with pure water without the addi-
tion of an approved corrosion inhibitor.

TIM-ID: 0000078599 - 003

38 | General Information | A001072/06E 2022-03

 3.1.6 Unsuitable materials in the coolant circuit
Components made of copper, zinc and brass materials
Unless various preconditions are observed, components made of copper, zinc and brass materials or with
galvanized surfaces in the coolant circuit (incl. supply and drain lines) can cause an electrochemical reaction
with base metals (e.g. with aluminum). As a result, components made of base metals are subject to corro-
sion or even corrosive pitting. The coolant circuit becomes leaky at these points.

Non-metallic materials
• Do not use EPDM or silicon elastomers if emulsifiable corrosion inhibitor oils are used or other oils are
introduced to the coolant circuit.

Coolant filter / filter downstream of plant components

• If such filters are used, only products that do not contain additives may be used.
Supplementary additives such as silicates, nitrites etc. can diminish the protective effect or service life of
a coolant and, possibly, attack the materials installed in the coolant circuit.

Information:
Consult the relevant specialist department of Rolls-Royce Solutions in case of doubt about the use of materi-
als on the engine / externally mounted components in coolant circuits.
TIM-ID: 0000080979 - 004

A001072/06E 2022-03 | General Information | 39

 3.1.7 Fresh water requirements – Series 4000
Only clean, clear water with values in accordance with those in the following table must be used for condi-
tioning the coolant with and without antifreeze. If the limit values for the water are exceeded, de-mineralized
water can be added to reduce the hardness or mineral content.
Parameter Minimum Maximum
Sum of alkaline earth met- 0 mmol/l 2.7 mmol/l
als *) 0°d 15°d
(Water hardness)
pH value at 20 °C 5.5 8.0
Chloride ions 100 mg/l
Sulphate ions 100 mg/l
Anions total 200 mg/l
Bacteria 103CFU (colony forming unit )/ml
Fungi, yeasts are not permitted

Table 26: Fresh water requirements, Series 4000

*) Common designations for water hardness in various countries:
1 mmol/l = 5.6°d = 100 mg/kg CaCO³
• 1°d = 17.9 mg/kg CaCO³, USA hardness
• 1°d = 1.79° French hardness
• 1°d = 1.25° English hardness

TIM-ID: 0000078621 - 001

40 | General Information | A001072/06E 2022-03

 3.1.8 Fresh water requirements – Series 400
Only clean, clear water with values in accordance with those in the following table must be used for prepar-
ing the coolant. If the limit values for the water are exceeded, de-mineralized water can be added to reduce
the hardness or mineral content.
General requirements Clear, colorless and free from
undissolved substances
pH value (25 °C) 7.4 to 8.5
Electric conductivity (25 °C) < 300 µS/cm
Sum total, alkaline earths 0.9 to 1.3 mmol/l
5 to 7 °dH
Chlorides < 80 mg/l
Sulfates < 70 mg/l
Iron < 0.2 mg/l
Bacteria < 103 CFU (colony forming unit )/ml
Fungi, yeasts are not permitted

Table 27: Fresh water requirements, Series 400

TIM-ID: 0000078708 - 001

A001072/06E 2022-03 | General Information | 41

 3.1.9 Fresh water requirements Series 500
Potable tap water with the limiting analysis values in the following table is suitable for producing the mixture.
Characteristic Unit Limit value
Appearance - Colorless, clear, free of mechanical contaminants
pH value at 25 °C - 8.2 to 8.5
Odor - Neutral
Alkaline earth metals (hardness) mmol/l Max. 0.02
°dH Max. 0.1
Conductivity at 25 °C μS/cm Max. 250
Chlorides mg/l Max. 10
Sulfates ppm Max. 150
Phosphate (PO4) mg/l 5 to 10

Table 28: Mixture water limit values

Important
The named limit values for the mixture water serve for technical orientation from which no legal claims can
be asserted because the water ratios are too different depending on the location.
The water can thus have numerous unknown combinations of secondary substances. The customer is re-
sponsible for safe operation.
Rolls-Royce Solutions recommends the use of a ready-mixed water-antifreeze mixture.

TIM-ID: 0000092000 - 002

42 | General Information | A001072/06E 2022-03

 3.2 Series 4000 gas engine – Marine application
3.2.1 Coolant – General information
Important
The coolant change depends on the operating time (hours/years) of the engine and on which operating
time is reached first.

Operating hours = preheating time + engine operating time

Important
All details are based on the coolant circuit on the engine side, no allowance is made for external add-on
components.

Important
In the case of an engine coolant circuit with no light metal elements but with add-on components contain-
ing light metal (e.g. external cooling system), the coolant approvals for cooling systems containing light
metal shall apply. If you have any doubts about a coolant application, consult your contact person.

Important
The use of products other than those listed will invalidate the warranty.

For details and special features, see “General” (→ Page 30) and “Unsuitable materials in the coolant circuit”
(→ Page 39).
Any deviant special agreements between the customer and Rolls-Royce Solutions remain valid.
TIM-ID: 0000078605 - 004

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 43

 3.2.2 Coolants without antifreeze – Concentrates for cooling systems free of light
metal
For details and special features, see chapter on “Coolants" (→ Page 30)

Coolants without antifreeze – concentrates

Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
Rolls-Royce Solutions Coolant CS100 Corrosion X 6000 / 2 X00057233 (20 l)
GmbH Inhibitor Concentrate X00057232 (210 l)
Also available through Rolls-
Royce Solutions Asia Pte.
Ltd.
Rolls-Royce Solutions Power Cool®Plus 6000 Con- X 6000 / 2 Colored green
America Inc. centrate 23533526 (1 gallon)
23533527 (5 gallons)
Available through Rolls-
Royce Solutions America
Inc.
Arteco NV Freecor NBI X 6000 / 2
Havoline Extended Life Cor- X 6000 / 2
rosion Inhibitor [EU Code
32765] (XLI)
BASF SE Glysacorr G93 green X 6000 / 2 X00054105 (barrel)
X00058062 (canister)
CCI Corporation A 216 X X 6000 / 2
CCI Manufacturing IL A 216 X X 6000 / 2 X00051509 (208 l)
Corporation
Chevron Corp. Texcool A – 200 X 6000 / 2
Chevron Lubricants Delo XLI Corrosion Inhibitor X 6000 / 2
- Concentrate
Chiron Chemicals Pty PrixMax RCP X 6000 / 2
Ltd
Detroit Diesel Corp. Power Cool Plus 2000 X X 6000 / 2
Power Cool Plus 6000 X X 6000 / 2 Colored red
Drew Marine Drewgard XTA X 6000 / 2
TIM-ID: 0000019146 - 010

ExxonMobil Mobil Delvac Extended Life X X 6000 / 2

Corrosion Inhibitor
Fleetguard DCA-4L X X X 2000 / 1
ImproChem COOL-18 X X 6000 / 2
Nalco Water An Ecolab ™
Alfloc 3477 X 6000 / 2
Company
Nalcool® 2000 X X 6000 / 2
Old World Industries Inc. Final Charge Extended Life X X 6000 / 2
Corrosion Inhibitor (A 216)

44 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Penray Pencool 2000 X X 6000 / 2
Total Lubrifiants Total WT Supra X 6000 / 2
Valvoline Zerex G-93 X 6000 / 2
OEM Advanced 93 X 6000 / 2
YORK SAS York 719 X 6000 / 2

Table 29:
TIM-ID: 0000019146 - 010

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 45

 3.2.3 Coolant without antifreeze – Ready mixtures for cooling systems free of light
metal
For details and special features, see chapter on “Coolants" (→ Page 30)

Coolant without antifreeze, ready mixtures

Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Rolls-Royce Solutions Coolant CS 10/90 Corro- X 6000 / 2 X00069385 (20 l)
GmbH sion Inhibitor Premix X00069386 (210 l)
(Sales region: Italy)
Chiron Chemicals Pty PrixMax RCP Premix (8 %) X 6000 / 2
Ltd
Nalco Water An Ecolab Alfloc™ 3443 (7 %) X 6000 / 2
Company

Table 30:

TIM-ID: 0000019147 - 011

46 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 3.2.4 Antifreeze – Concentrates for cooling systems free of light metal
For details and special features, see chapter "Coolants" (→ Page 30).

Antifreeze, concentrates
Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Rolls-Royce Solutions Coolant AH100 Antifreeze X X 9000 / 5 X00057231 (20 l)
GmbH Concentrate X00057230 (210 l)
Also available from Rolls-
Royce Solutions Asia Pte.
Ltd.
Alliance Automotive NAPA Premium Kühler- X X 9000 / 5
Service GmbH schutz N48
AVIA AG Antifreeze APN X X 9000 / 5
Antifreeze APN-S X 9000 / 3
BASF SE Glysantin G48 blue green X X
® ® 9000 / 5 X00058054 (25 l)
X00058053 (210 l)
Glysantin® G40® pink (con- X X 9000 / 3 X00066724 (20 l)
centrate) X00066725 (210 l)
Application concentration
40 to 50% by volume
Glysantin® G30® pink X 9000 / 3 X00058072 (canister)
X00058071 (barrel)
BayWa AG Tectrol Coolprotect X X 9000 / 5
BP Lubricants ARAL Antifreeze Extra X X 9000 / 5
Castrol Castrol Radicool NF X X 9000 / 5
CCI Corporation L415 X X 9000 / 3
Classic Schmierstoff Classic Kolda UE G48 X X 9000 / 5
GmbH + Co. KG
Comma Oil & Chemicals Comma Xstream ® G30® X 9000 / 3
Ltd. Antifreeze Coolant Concen-
trate
Comma Xstream ® G48® X X 9000 / 5
Antifreeze Coolant Concen-
trate
TIM-ID: 0000080984 - 007

COPARTS Autoteile CAR1 Premium Longlife X X 9000 / 5

GmbH Kühlerschutz C48
Daimler Trucks North Alliance OAT Extended Life X X 9000 / 3
America Coolant
Detroit Diesel Corp. Power Cool Plus Coolant X X 9000 / 3
Drew Marine Drewgard ZX X 9000 / 3

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 47

Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
ExxonMobil Mobil Delvac Extended Life X X 9000 / 3
Coolant
Mobil Antifreeze Advanced X 9000 / 3
Mobil Antifreeze Extra X X 9000 / 5
Esso Antifreeze Advanced X 9000 / 3
Esso Antifreeze Extra X X 9000 / 5
Finke Mineralölwerk AVIATICON Finkofreeze F30 X 9000 / 3
GmbH AVIATICON Finkofreeze F40 X X 9000 / 3 Application concentration
40 to 50% by volume
AVIATICON Finkofreeze F48 X X 9000 / 5
Fuchs Petrolub SE Maintain Fricofin X X 9000 / 5
Maintain Fricofin G12 Plus X 9000 / 3 X00058074 (canister)
X00058073 (barrel)
Gazpromneft-Lubricants G-Energy Antifreeze SNF X 9000 / 3
Ltd.
Kuttenkeuler Kuttenkeuler Antifreeze X X 9000 / 5
ANF KK48
Glyostar® ST48 X X 9000 / 5
INA Maziva Ltd. INA Antifriz Al Super X X 9000 / 5
LLK-International (Lukoil Lukoil Antifreeze HD G12 K X 9000 / 3
Lubricants Co
Lukoil Lubricants Europe Lukoil Coolant Plus X X 9000 / 5
GmbH Lukoil Coolant SF X 9000 / 3
Lukoil Coolant SOT X X 9000 / 3 Application concentration
40 to 50% by volume
Mitan Mineralöl GmbH Alpine C30 X 9000 / 3
Alpine C48 X X 9000 / 5
MJL Bangladesh Limited Omera Premium Coolant X 9000 / 3
MOFIN Deutschland MOFIN Kühlerschutz M40 X X 9000 / 3 Application concentration
GmbH & Co KG Extra 40 to 50% by volume
MOFIN Kühlerschutz M48 X X 9000 / 5
Premium Protect
TIM-ID: 0000080984 - 007

Motorex AG Motorex Coolant G48 X X 9000 / 5

Motorex Coolant M 4,0 X X 9000 / 3 Application concentration
Concentrate 40 to 50% by volume
Nalco Water An Ecolab Nalcool NF 48 C X X 9000 / 5
Company
Navistar Inc. Fleetrite Nitrite-Free Ex- X X 9000 / 3
tended Life Coolant

48 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Old World Industries Inc. Blue Mountain Heavy Duty X X 9000 / 3
Extended Life Coolant
Final Charge Global Extend- X X 9000 / 3
ed Life Coolant Antifreeze
Panolin AG Panolin Anti-Frost MT-325 X X 9000 / 5
Puma Energy Interna- Puma HD Hybrid Coolant X X 9000 / 3 Application concentration
tional S.A. 40 to 50% by volume
Raloy Lubricantes Antifreeze Long Life NF-300 X X 9000 / 5
Concentrate
Recochem Inc. HD Expert ™ Endurance X X 9000 / 3
SMB - Sotragal / Mont Antigel Power Cooling Con- X X 9000 / 5
Blanc centrate
Total Lubrifiants Glacelf MDX X X 9000 / 5
Valvoline Zerex G-48 X X 9000 / 5
Zerex G-40 (concentrate) X X 9000 / 3 Material number (USA):
800 180 (Drum)
Application concentration
40 to 50% by volume
Zerex G-30 X 9000 / 3
OEM Advanced G30 X 9000 / 3
OEM Advanced G40 X X 9000 / 3 Application concentration
40 to 50% by volume
OEM Advanced G48 X X 9000 / 5
Volvo Trucks Road Choice Nitrite-Free X X 9000 / 3
OAT Extended Life Coolant
YORK SAS York 716 X X 9000 / 5

Table 31: Antifreeze, concentrates

TIM-ID: 0000080984 - 007

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 49

 3.2.5 Antifreeze – Concentrates for special applications
For details and special features, see chapter on “Coolants" (→ Page 30)

Concentrates for special applications

Manufacturer Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
BASF SE Glysantin® G30® pink X 9000 / 3 Application concentration
40-65% by vol.
For use in arctic regions
X00058072 (canister)
X00058071 (barrel)

Table 32:

Working concentration
Application concentrations, antifreeze on ethyl- Antifreeze in accordance with ASTM D 1177
ene glycol basis
40% by volume -25 °C
45% by volume -31 °C
50% by volume -37 °C
55% by volume -45 °C
60% by volume -52 °C
65% by volume -60 °C

Table 33:
Important
From approx. 65% by vol. onwards, there is a reversal of the antifreeze behavior (bath effect), i.e. with an
increasing application concentration, antifreeze protection is no longer increased but is reduced.
TIM-ID: 0000019151 - 007

50 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 3.2.6 Antifreeze – Ready mixtures for cooling systems free of light metals
Antifreeze, ready mixtures
For details and special features, see chapter "Coolants" (→ Page 30).
Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Rolls-Royce Solutions Coolant AH 35/65 Anti- X X 9000 / 5 X00069382 (20 l)
GmbH freeze Premix X00069383 (210 l)
X00069384 (1000 l)
(sales region: Italy)
Coolant AH 40/60 Anti- X X 9000 / 5 X00070533 (20 l)
freeze Premix X00070532 (1000 l)
(sales region: England,
Spain)
Coolant AH 50/50 Anti- X X 9000 / 5 X00070528 (20 l)
freeze Premix X00070527 (1000 l)
(sales region: England)
Rolls-Royce Solutions Power Cool ® Universal X X 9000 / 5 800085 (5 gallons)
America Inc. 35/65 mix 800086 (55 gallons)
Power Cool ® Universal X X 9000 / 5 800071 (5 gallons)
50/50 mix 800084 (55 gallons)
Bantleon Avilub Antifreeze Mix (50 %) X X 9000 / 5 X00049213 (210 l)
BayWa AG Tectrol Coolprotect Mix X 9000 / 3 Antifreeze protection up to
3000 -24 °C
Castrol Castrol Radicool NF Premix X X 9000 / 5
(45 %)
CCI Corporation L 415 (50 %) X X 9000 / 3
Cepsa Comercial Petró- Xtar Super Coolant Hybrid X X 9000 / 5
leo S.A.U NF 50 %
Daimler Trucks North Alliance 50/50 Prediluted X X 9000 / 3
America OAT Extended Life Coolant
Detroit Diesel Corp. Power Cool Plus Prediluted X X 9000 / 3
Coolant (50/50)
ExxonMobil Mobil Delvac Extended Life X X 9000 / 3
Prediluted Coolant (50/50)
Finke Mineralölwerk AVIATICON Finkofreeze F30 X 9000 / 3
TIM-ID: 0000080986 - 006

GmbH RM 40:60 +
AVIATICON Finkofreeze F48 X X 9000 / 5
RM 50:50
LLK-International (Lukoil Lukoil Antifreeze HD G12 X 9000 / 3
Lubricabts Co) (50%)

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 51

Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Motorex AG Motorex Coolant G48 ready X X 9000 / 5
to use (50/50)
Motorex Coolant M 4,0 X X 9000 / 3 Antifreeze protection up to
ready to use -38 °C
(50% by vol.)
Navistar Inc. Fleetrite 50/50 Prediluted X X 9000 / 3
Nitrite-Free Extended Life
Coolant
Old World Industries Inc. Blue Mountain Heavy Duty X X 9000 / 3
Extended Life Prediluted
Coolant (50/50)
Final Charge Global Extend- X X 9000 / 3
ed Life Predilluted Cool-
ant / Antifreeze (50/50)
Puma Energy Interna- Puma HD Hybrid Coolant X X 9000 / 3 (50% by vol.)
tional S.A. 5050
Raloy Lubricantes Antifreeze Long Life NF-300 X X 9000 / 5
Ready-to-Use (50/50)
Recochem Inc. HD Expert™ Endurance X X 9000 / 3
50-50 Prediluted
SMB - Sotragal / Mont L.R.-30 Power Cooling X X 9000 / 5
Blanc (44 %)
L.R.-38 Power Cooling X X 9000 / 5
(52 %)
Total Lubrifiants Coolelf MDX -26 °C X X 9000 / 5
Coolelf MDX -37 °C X X 9000 / 5
Tosol-Sinzez Glysantin Alu Protect/G30 X 9000 / 3
Ready Mix
Glysantin Protect Plus/G48 X X 9000 / 5
Ready Mix
Valentin Energie GmbH Valentin Coolant Plus X 9000 / 3
-25 °C Ready
Valvoline Zerex G-48 premix 50% X X 9000 / 5
OEM Advanced 48 premix X X 9000 / 5
TIM-ID: 0000080986 - 006

50%
Volvo Trucks Road Choice 50/50 Predi- X X 9000 / 3
luted Nitrite-Free OAT Ex-
tended Life Coolant
YPF S.A. Argentina Kriox MTL50 X X 9000 / 3

Table 34: Antifreeze, ready mixtures

52 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 3.3 Series 4000 gas engine – Generator application and engine-
generator set
3.3.1 Coolant – General information
Important
The coolant change depends on the operating time (hours/years) of the engine and on which operating
time is reached first.

Operating hours = preheating time + engine operating time

Important
All details are based on the coolant circuit on the engine side, no allowance is made for external add-on
components.

Important
In the case of an engine coolant circuit with no light metal elements but with add-on components contain-
ing light metal (e.g. external cooling system), the coolant approvals for cooling systems containing light
metal shall apply. If you have any doubts about a coolant application, consult your contact person.

Important
The use of products other than those listed will invalidate the warranty.

For details and special features, see “General” (→ Page 30) and “Unsuitable materials in the coolant circuit”
(→ Page 39).
Any deviant special agreements between the customer and Rolls-Royce Solutions remain valid.
TIM-ID: 0000078605 - 004

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 53
 3.3.2 Coolant without antifreeze – Concentrates for cooling systems containing light
metal
For details and special features, see chapter on “Coolants” (→ Page 30)

Important
For Series 1163-03 and 1163-04 marine engines, only coolants marked with an asterisk * in the product/
brand name may be used.

Coolants without antifreeze – concentrates

Manufacturer Product/brand name Inhibitors Operating time Comments /
Hours / Years Material number
Organic
Silicon

Molybdate
Nitrite
Phosphatized
Rolls-Royce Solutions Coolant CS100 Corrosion X 6000 / 2 X00057233 (20 l)
GmbH Inhibitor Concentrate* X00057232 (210 l)
Also available from Rolls-
Royce Solutions Asia Pte.
Ltd.
Rolls-Royce Solutions Power Cool® Plus 6000 X 6000 / 2 colored green
America Inc. Concentrate* 23533526 (1 gallon)
23533527 (5 gallons)
Available from Rolls-Royce
Solutions America Inc.
Arteco NV Freecor NBI X 6000 / 2
BASF SE Glysacorr G93 green* X 6000 / 2 X00054105 (barrel)
X00058062 (canister)
CCI Corporation A 216 X X 6000 / 2
CCI Manufacturing IL A 216 X X 6000 / 2 X00051509 (208 l)
Corporation
Chevron Corp. Texcool A – 200 X 6000 / 2
Detroit Diesel Corp. Power Cool Plus 6000 X X 6000 / 2 colored red
Drew Marine Drewgard XTA* X 6000 / 2
ExxonMobil Mobil Delvac Extended Life X X 6000 / 2
Corrosion Inhibitor
Old World Industries Inc. Final Charge Extended Life X X 6000 / 2
Corrosion Inhibitor (A 216)
Valvoline ZEREX G-93* X 6000 / 2
TIM-ID: 0000019105 - 009

OEM Advanced 93* X 6000 / 2

YORK SAS York 719* X 6000 / 2

Table 35:

54 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 3.3.3 Coolant without antifreeze – Ready mixtures for cooling systems containing
light metal
For details and special features, see chapter on “Coolants” (→ Page 30)
Important
For Series 1163-03 and 1163-04 marine engines, only coolants marked with an asterisk * in the product
name may be used.

Coolant without antifreeze, ready mixtures

Manufacturer Product name Inhibitors Operating time Comments /
Hours / Years Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
Rolls-Royce Solutions Coolant CS10/90 Corrosion X 6000 / 2 X00069385 (20 l)
GmbH Inhibitor Premix* X00069386 (210 l)
(Sales region: Italy)

Table 36:
TIM-ID: 0000054558 - 008

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 55
 3.3.4 Antifreeze – Concentrates for cooling systems containing light metal
For details and special features, see chapter "Coolants" (→ Page 30).

Antifreeze, concentrates
Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
Rolls-Royce Solutions Coolant AH100 Antifreeze X X 9000 / 5 X00057231 (20 l)
GmbH Concentrate X00057230 (210 l)
Also available from Rolls-
Royce Solutions Asia Pte.
Ltd.
Alliance AutomotiveSer- NAPA Premium Kühler- X X 9000 / 5
vice GmbH schutz N48
AVIA AG Antifreeze APN X X 9000 / 5
Antifreeze APN-S X 9000 / 3
BASF SE ®
GLYSANTIN G05 ® X X 9000 / 5
GLYSANTIN® G48® blue X X 9000 / 5 X00058054 (25 l)
green X00058053 (210 l)
GLYSANTIN® G30® pink X 9000 / 3 X00058072 (canister)
X00058071 (barrel)
GLYSANTIN® G40® pink X X 9000 / 3 X00066724 (20 l)
(concentrate) X00066725 (210 l)
Concentration for use: 40
to 50% by volume
BayWa AG Tectrol Coolprotect X X 9000 / 5
BP Lubricants ARAL Antifreeze Extra X X 9000 / 5
Castrol Castrol Radicool NF X X 9000 / 5
CCI Corporation L415 X X 9000 / 3
Clariant Genantin Super X X 9000 / 3
Classic Schmierstoff Classic Kolda UE G48 X X 9000 / 5
GmbH + Co. KG
Comma Oil & Chemicals Comma Xstream ® G30® X 9000 / 3
Ltd. Antifreeze Coolant Concen-
trate
Comma Xstream ® G48® X X 9000 / 5
TIM-ID: 0000080987 - 006

Antifreeze Coolant Concen-

trate
COPARTS Autoteile CAR 1 Premium Longlife X X 9000 / 5
GmbH Kühlerschutz C48
Daimler Trucks North Alliance OAT Extended Life X X 9000 / 3
America Coolant

56 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Detroit Diesel Corp. Power Cool Antifreeze X X 9000 / 3
Power Cool Plus Coolant X X 9000 / 3
Power Cool Diesel Engine X X 9000 / 3
Coolant
Drew Marine Drewgard ZX X 9000 / 3
ExxonMobil Mobil Delvac Extended Life X X 9000 / 3
Coolant
Mobil Antifreeze Advanced X 9000 / 3
Mobil Antifreeze Extra X X 9000 / 5
Mobil Antifreeze Special X X 9000 / 5
Mobil Heavy Duty Coolant X X 9000 / 3
Mobil Mining Coolant X X 9000 / 3
Esso Antifreeze Advanced X 9000 / 3
Esso Antifreeze Extra X X 9000 / 5
Finke Mineralölwerke AVIATICON Finkofreeze F30 X 9000 / 3
GmbH AVIATICON Finkofreeze F40 X X 9000 / 3 Application concentration:
40 to 50% by volume
AVIATICON Finkofreeze F48 X X 9000 / 5
Fuchs Petrolub SE Maintain Fricofin X X 9000 / 5
Maintain Fricofin G12 Plus X 9000 / 3 X00058074 (canister)
X00058073 (barrel)
Gazpromneft-Lubricants G-Energy Antifreeze SNF X 9000 / 3
Ltd.
Krafft S.L.U Refrigerante ACU 2300 X X 9000 / 3 X00058075 (barrel)
Kuttenkeuler Kuttenkeuler Antifreeze X X 9000 / 5
ANF KK48
Glyostar® ST48 X X 9000 / 5
INA Maziva Ltd. INA Antifriz Al Super X X 9000 / 5
LLK-International (Lukoil Lukoil Antifreeze HD G 12 K X 9000 / 3
Lubricants Co)
Lukoil Lubricants Europe Lukoil Coolant Plus X X 9000 / 5
TIM-ID: 0000080987 - 006

GmbH Lukoil Coolant SF X 9000 / 3

Lukoil Coolant SOT X X 9000 / 3 Application concentration:
40 to 50% by volume
Mitan Mineralöl GmbH Alpine C30 X 9000 / 3
Alpine C48 X X 9000 / 5
MJL Bangladesh Limited Omera Premium Coolant X 9000 / 3
Lube Oil Blending Plant
East Patenga

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 57
Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
MOFIN Deutschland MOFIN Kühlerschutz M48 X X 9000 / 5
GmbH & Co KG Premium Protect
MOFIN Kühlerschutz M40 X X 9000 / 3 Application concentration:
Extra 40 to 50% by volume
Motorex AG Motorex Coolant G48 X X 9000 / 5
Motorex Coolant M 4,0 X X 9000 / 3 Concentration for use: 40
Concentrate to 50% by volume
Nalco Water An Ecolab Nalcool NF 48 C X X 9000 / 5
Company
Navistar Inc. Fleetrite Nitrite-Free Ex- X X 9000 / 3
tended Life Coolant
Old World Industries Inc. Blue Mountain Heavy Duty X X 9000 / 3
Extended Life Coolant
Fleetcharge SCA Pre- X X 9000 / 3
charged Coolant/ Anti-
freeze
Final Charge Global Extend- X X 9000 / 3
ed Life Coolant Antifreeze
Peak Heavy Duty Coolant X X 9000 / 3
Panolin AG Panolin Anti-Frost MT-325 X X 9000 / 5
Penske Power Systems Power Cool - HB500 Cool- X X 9000 / 3
ant Concentrate
Puma Energy Interna- Puma HD Hybrid Coolant X X 9000 / 3 Concentration for use: 40
tional S.A to 50% by volume
Raloy Lubricantes Antifreeze Long Life NF-300 X X 9000 / 3
Concentrate
Recochem Inc. R542 X X 9000 / 3
HD Expert™ Endurance X X 9000 / 3
SMB - Sotragal / Mont Antigel Power Cooling Con- X X 9000 / 5
Blanc centrate
Total Lubrifiants Glacelf MDX X X 9000 / 5
Valvoline Zerex G-05 X X 9000 / 5
Zerex G-48 X X 9000 / 5
TIM-ID: 0000080987 - 006

Zerex G-30 X 9000 / 3

ZEREX G40 (Konzentrat) X X 9000 / 3 Concentration for use: 40
to 50% by volume
Material number (USA):
800180 (Drum)
OEM Advanced 30 X 9000 / 3
OEM Advanced 48 X X 9000 / 5
OEM Advanced 40 X X 9000 / 3 Concentration for use: 40
to 50% by volume

58 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Volvo Trucks Road Choice Nitrite-Free X X 9000 / 3
OAT Extended Life Coolant
YORK SAS York 716 X X 9000 / 5

Table 37: Antifreeze, concentrates

TIM-ID: 0000080987 - 006

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 59
 3.3.5 Antifreeze – Concentrates for special applications
For details and special features, see chapter on “Coolants" (→ Page 30)

Concentrates for special applications

Manufacturer Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
BASF SE Glysantin® G30® pink X 9000 / 3 Application concentration
40-65% by vol.
For use in arctic regions
X00058072 (canister)
X00058071 (barrel)

Table 38:

Working concentration
Application concentrations, antifreeze on ethyl- Antifreeze in accordance with ASTM D 1177
ene glycol basis
40% by volume -25 °C
45% by volume -31 °C
50% by volume -37 °C
55% by volume -45 °C
60% by volume -52 °C
65% by volume -60 °C

Table 39:
Important
From approx. 65% by vol. onwards, there is a reversal of the antifreeze behavior (bath effect), i.e. with an
increasing application concentration, antifreeze protection is no longer increased but is reduced.
TIM-ID: 0000019151 - 007

60 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 3.3.6 Antifreeze – Ready mixtures for cooling systems containing light metals
For details and special features, see chapter "Coolants" (→ Page 30).

Antifreeze, ready mixtures

Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon

Molybdate
Nitrite
Phosphatized
Rolls-Royce Solutions Coolant AH 35/65 Anti- X X 9000 / 5 X00069382 (20 l)
GmbH freeze Premix X00069383 (210 l)
X00069384 (1000 l)
(sales region: Italy)
Coolant AH 40/60 Anti- X X 9000 / 5 X00070533 (20 l)
freeze Premix X00070532 (1000 l)
(sales region: England,
Spain)
Coolant AH 50/50 Anti- X X 9000 / 5 X00070528 (20 l)
freeze Premix X00070527 (1000 l)
(sales region: England)
Rolls-Royce Solutions Power Cool ® Universal X X 9000 / 5 800085 (5 gallons)
America Inc. 35/65 mix 800086 (55 gallons)
Power Cool ® Universal X X 9000 / 5 800071 (5 gallons)
50/50 mix 800084 (55 gallons)
Power Cool ® Off-Highway X X 9000 / 5 23533531 (5 gallons)
Coolant 50/50 Premix 23533532 (55 gallons)
Bantleon Avilub Antifreeze Mix (50 %) X X 9000 / 5 X00049213 (210 l)
BayWa AG Tectrol Coolprotect Mix X 9000 / 3 Antifreeze protection up to
3000 -24 °C
Castrol Castrol Radicool NF Premix X X 9000 / 5
(45 %)
CCI Corporation L 415 (50 %) X X 9000 / 3
Cespa Comercial Petró- Xtar Super Coolant Hybrid X X 9000 / 5
leo S.A.U. NF 50%
Detroit Diesel Corp. Power Cool Plus Prediluted X X 9000 / 3
Coolant (50/50)
Power Cool Prediluted X X 9000 / 3
(50/50) Diesel Engine Cool-
ant
TIM-ID: 0000078607 - 007

ExxonMobil Mobil Delvac Extended Life X X 9000 / 3

Prediluted Coolant (50/50)
Mobile Heavy Duty 50/50 X X 9000 / 3
Prediluted Coolant
Mobile Mining 50/50 Predi- X X 9000 / 3
luted Coolant

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 61
Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Finke Mineralölwerk AVIATICON Finkofreeze F30 X 9000 / 3
GmbH RM 40:60 +
AVIATICON Finkofreeze F48 X X 9000 / 5
RM 50:50
LLK-International (Lukoil Lukoil Antifreeze HD G 12 X 9000 / 3
Lubricants Co) (50%)
Motorex AG Motorex Coolant G48 ready X X 9000 / 5
to use (50/50)
Motorex Coolant M 4,0 X X 9000 / 3 Antifreeze protection up to
ready to use -38 °C
(50% by vol.)
Navistar Inc. Fleetrite 50/50 Prediluted X X 9000 / 3
Nitrite-Free Life Coolant
Old World Industries Inc. Blue Mountain Heavy Duty X X 9000 / 3
Extended Life Prediluted
Coolant (50/50)
Final Charge Global Extend- X X 9000 / 3
ed Life Predilluted Cool-
ant / Antifreeze (50/50)
Fleet Charge SCA Pre- X X 9000 / 3
charged 50/50 Prediluted
Coolant
Penske Power Systems Power Cool - HB500 Premix X X 9000 / 3
50/50
Puma Energy Interna- Puma HD Hybrid Coolant X X 9000 / 3 (50% by vol.)
tional S.A. 5050
Raloy Lubricantes Antifreeze Long Life NF-300 X X 9000 / 5
Ready-to-Use (50/50)
Recochem Inc. HD Expert™ Endurance X X 9000 / 3
50-50 Prediluted
SMB - Sotragal / Mont L.R.-30 Power Cooling X X 9000 / 5
Blanc (44 %)
L.R.-38 Power Cooling X X 9000 / 5
(52 %)
Tosol-Sintez Glysantin Alu Protect/G30 X 9000 / 3
TIM-ID: 0000078607 - 007

Ready Mix
Glysantin Protect Plus/G48 X X 9000 / 5
Ready Mix
Total Lubrifiants Coolelf MDX -26 °C X X 9000 / 5
Coolelf MDX -37 °C X X 9000 / 5
Valentin Energie GmbH Valentin Coolant Plus X 9000 / 3
-25 °C Ready

62 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Manufacturer Product/Brand name Inhibitors Operating time Comments /
Hour / Year Material number

Organic
Silicon
Nitrite
Phosphatized
Molybdate
Valvoline Zerex G-05 50/50 Mix X X 9000 / 5
Zerex G-48 premix 50% X X 9000 / 5
OEM Advanced 48 premix X X 9000 / 5
50%
Volvo Trucks Road Choice 50/50 Predi- X X 9000 / 3
luted Nitrite-Free OAT Ex-
tended Life Coolant
YPF S.A. Argentina Kriox MTL50 X X 9000 / 3

Table 40: Antifreeze – Ready mixtures for cooling systems containing light metals
TIM-ID: 0000078607 - 007

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 63
 3.4 Series 400 gas engine – Engine-generator set
3.4.1 Approved coolants
Important
The use of products other than those listed will invalidate the warranty.

Antifreeze, ready mixtures (silicate-free)

Manufacturer/Supplier Designation
BayWa AG Tectrol Coolprotect MIX3000*
Montana Kühlerfrostschutz BHKW -25°*
Valentin Energie GmbH Coolant Plus -25° Ready*
* Extended change interval possible
Table 41:

Antifreeze, concentrates
Manufacturer/Supplier Designation
BASF Glysantin ® G30 ®pink
Aral Antifreeze Silikatfrei

Table 42:

Information on warranty
It is strongly recommended to use ready mixed antifreezes for the engine cooling circuit.
If these ready mixtures are used, the following requirements will be met:
• The ratio of water to antifreeze is set correctly
• The used (fresh) water complies with the specifications set out in “Requirements of engine coolant".
The service lives of components will be shortened if the water used does not comply with the specifications.
In such a case, there is a risk of deposits forming for many components, which can lead to a reduction in
heat transfer and hence a reduction in functionality (heat exchanger) or to overheating of the components.
Observe the following with "self-mixing" of coolant:
• Only use the approved silicate-free antifreezes with the specified ratio to water
• A form must be signed confirming that the water used fulfills the requirements set out in the Fluids and
Lubricants Specifications.
Check the concentration at regular intervals in accordance with the maintenance schedule. The coolant
should be checked once a year or each time it is added, whichever comes first. Due to aging, the coolant
filling must be replaced after 25,000 operating hours or after 3 years at the latest.
TIM-ID: 0000053805 - 007

64 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 3.5 Series 500 Gas Engine - Engine-Generator Set
3.5.1 Coolants – General information
Antifreezes checked and approved by Rolls-Royce Solutions guarantee sufficient protection against frost,
corrosion and cavitation, do not attack gaskets and hoses and do not foam, see (→ Page 67).
To ensure continuous, trouble-free operation of engine-generator sets, the coolant used must always have a
suitable composition all year round that guarantees protection against frost and corrosion.
TIM-ID: 0000091998 - 002

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 65

 3.5.2 Coolant – Check and replacement
The coolants used by Rolls-Royce Solutions are subject to natural aging and their condition must therefore
be checked regularly.
Coolant losses must always be replaced with a mixture of water and antifreeze. The mixing volume ratio de-
pends on the engine and selected antifreeze.
Rolls-Royce Solutions expressly points out that the water quality must be checked when topping up supple-
mentary water and that the values must be observed, see (→ Page 42).
For topping up, Rolls-Royce Solutions recommends the use of a ready-mixed water-antifreeze mixture.
To maintain the cooling capacity of the engine, the coolant quality must be checked after 2,000 operating
hours. The following must be observed in this case:
• Check the coolant concentration every three months using a hydrometer or refractometer
• Never allow the antifreeze concentration to fall below 40% by volume
• The coolant must be replaced completely at the latest after the interval predefined in the Maintenance
Schedule of the respective plant.
• Observe the limit values (→ Table 42)
• Vent the cooling system, adjust coolant pressure if necessary
Important
Coolants must not be mixed. Otherwise there is a danger of engine damage.
Cooling systems only work reliably if they are operated with sufficient upstream pressure and are correctly
vented. On Rolls-Royce Solutions plants, the respective minimum pressure is saved as a warning value in
the control system. This may deviate, however, due to local conditions. It is recommended to always set
the pressure to the upper limit.

When extracting a sample to checking the coolant, fill a clean vessel using a suitable hose. 100 ml are al-
ready sufficient. Select a suitable extraction point, the vent points of the coolant circuit. As the plants are
under pressure, for safety reasons the sample must be extracted at low temperatures below 60 °C. Other-
wise explosive evaporation of the coolant is possible. It is essential to observe the respective safety instruc-
tions!

Limit values for coolants

Characteristic Unit Limit value
Appearance - Change with brown discoloration
pH value at 25 °C - Min. 7.5
Odor - Change in case of odor of solvents
Antifreeze °C Min. -20
TIM-ID: 0000091999 - 002

66 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 3.5.3 Approved coolants
Only approved antifreezes provide the protection for the engine cooling system according to Rolls-Royce Sol-
utions requirements. The concentrates and the ready-mixed water-antifreeze mixtures also provide the nec-
essary corrosion protection.

Approved coolants
Coolant manu- Product Mixing volume ratio Operating Note
facturer hours hour /
year
BASF Glysantin® G48® Concentrate/water 16000/2
bluegreen 50/50 or ready-mixed
Caltex, Chev- Havoline® ELC Concentrate/water 16000/2 Alternative, only for
ron, Texaco Dex-Cool® 50/50 or ready-mixed America, ethylene-glycol-
based
Caltex, Chev- Delo® ELC PG Concentrate/water 16000/2 Alternative, only for
ron, Texaco 50/50 or ready-mixed America, propylene-gly-
col-based
Vavoline Zerex G48 Concentrate/water 16000/2 Alternative, only for
50/50 or ready-mixed America, ethylene-glycol-
based

Table 43: Approved coolants

Avoid coolant concentrations above 50%.
Important
The coolant change depends on the operating time (hours/years) of the engine and on which operating
time is reached first.

Important
All details are based on the coolant circuit on the engine side, no allowance is made for external add-on
components.
TIM-ID: 0000092001 - 003

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 67

 4 Fuels
4.1 General Information
4.1.1 Fuels – Usage
Important information
The specified limit values for moisture in the fuel must be observed because otherwise the warranty shall
become void.

Important information
The fuel must not contain any corrosive compounds (e.g. siloxanes, phosphor, arsenic, heavy metal, sulfur,
ammonia, chlorine, fluorine, bromide and iodine compounds).
The specified limit values must be observed because otherwise the warranty shall become void.

Gas engines must only be operated with the gases approved for the respective gas engine type.
For operation with natural gas from the public grid, the following must be confirmed by the responsible gas
utility company prior to commissioning of the engine at the latest:
• Whether the minimum methane number and calorific value range specified on the respective data sheet
are observed
• Whether butane or a propane-air mixture are added at times
• Whether biogas feeding into the natural gas grid is also possible (coordinate through factory request). A
gas analysis must be available.

The usage options of the approved gas types must be checked by gas analysis at least twice a year. The
following changes can thus be detected and measures initiated:
• Gas composition
• Harmful elements in the gas
In the entire application and operating range of the engine, the use of fuels is restricted to purely gaseous
fuels. Liquid fuels are not permitted.
The fuel must be technically free of mist, dust and liquid. Condensation in the gas system must be prevented
by suitable measures (dehumidification, protection against cooling down, heating, etc.). Corrosive constitu-
ents may only be present in the concentrations set out below (→ Page 70).
If the quality of the raw gas exceeds the sulfur limit values, a gas desulferization system that is designed for
the quality of the gas must be installed.
TIM-ID: 0000078925 - 001

68 | Fuels | A001072/06E 2022-03

 4.1.2 Requirements for fuel gas
Requirements for mtu gas engines
Designation Unit Limit value Note
Methane number -- ≥70: Engine configura- Adjustments may prove necessary
tion for standard water depending on model type, power and
content in intake air fuel consumption.
≥75: Engine configura- Observe the Operating Instructions
tion for high water con- (Technical data).
tent in intake air Consult with the manufacturer before
operating with lower values as a gas
analysis is required in such case.
Knock monitoring reduces engine
power.
Methane number calculated in ac-
cordance with DIN EN 16726.

Table 44: Requirements for fuel gas for mtu gas engines
TIM-ID: 0000095894 - 002

A001072/06E 2022-03 | General Information | 69

 4.1.3 Main constituents of natural gas and fuel gases of biogenic origin
Generally applicable limits for the main constituents of natural gas and fuel
gases of biogenic origin
Components that may be used for gas engines are listed in the following tables:
• Generally applicable limits for the main constituents of natural gas (→ Table 45)
• Generally applicable limits for the main constituents of fuel gases of biogenic origin (→ Table 46)

Main constituents of natural gas

Component Unit Value range (maximum
value)
CH4 % by vol. 80 to 100
C2H6 (or sum of C2Hx) % by vol. < 12
C3H8 (or sum of C3Hx) % by vol. <9
C4H10 (or sum of C4Hx) % by vol. <2
C5H12 % by vol. <0.3
Hydrocarbons C5+ % by vol. < 0.1
CO2 % by vol. < 10
N2 % by vol. < 15
Sum of CO2 + N2 % by vol. < 15
O2 % by vol. <3
H2 % by vol. <2
CO % by vol. < 0.2

Table 45:
The above-listed components apply to natural gas compositions. Components other than those listed above
(as well as trace elements) are not usual for natural gas compositions.
If the components of the natural gas exceed the listed maximum values, consultation must be made with
Rolls-Royce Solutions before using this natural gas.

Main components of fuel gases of biogenic origin, mainly from fermentation

processes (values are specified air-free)
Component Unit Value range (maximum
value)
CH4 % by vol. 40 to 85
CO2 % by vol. 20 to 55
N2 % by vol. < 10
TIM-ID: 0000078928 - 004

O2 % by vol. <3
H2 % by vol. <2
CO % by vol. < 0.2

Table 46:
The above-listed components apply to fuel gases of biogenic origin. Components other than those listed
above (as well as trace elements) are not usual for such gas fuels.
If the components of the natural gas exceed the listed maximum values, consultation must be made with
Rolls-Royce Solutions before using this biogas.

70 | General Information | A001072/06E 2022-03

 4.1.4 Liquid Natural Gas (LNG)
Notes on Liquid Natural Gas (LNG)
Note that the LNG Bunker Delivery Note in the IGF Code specifies component fractions as mass percent. The
representation deviates significantly from other common representations in Mol or volume percent.
LNG tanks may only be filled with LNG to 90% of their overall volume. Any additional heat in the tank causes
small amounts of liquid gas to vaporize and accumulate as gas in the “boil-off” phase. The composition of
this boil-off gas depends on the composition of the liquid phase. The N2 component in the boil-off phase may
by 20x greater than the nitrogen content in the liquid phase. In general, boil-off gas can contain 20 % by
volume nitrogen and 80 % by volume methane as well as traces of ethane.
LNG as per EN1160 has a lower methane limit mass fraction of 75% and an upper nitrogen limit mass frac-
tion of 5%.
The use of LNG with a nitrogen content of <1 m/m% is recommended to avoid rollover effects.
The term “rollover” is used to describe vaporization and the subsequent increase in pressure this entails as a
result of stratification and the rapid mixing of superheated liquid from the lower layer with the upper layer
under the hydrostatic head exerted by the latter.
LNG contains no significant, or only traces of CO2, as CO2 solidifies at temperatures below -56 °C and the
pressures around 5.2 bar which generally prevail in such tanks. CO2 sublimates at -78.5 °C under normal
pressure conditions.
TIM-ID: 0000081014 - 001

A001072/06E 2022-03 | General Information | 71

 4.1.5 Silicon and sulfur compounds in the fuel gas
Silicon compounds in the gas lead to deposits and promote wear. Even catalytic converters are deactivated
by these compounds. Damage caused by silicon and sulfur compounds is not covered by the warranty.
For determination of the Si concentration in the lube oil and its limit value, refer to chapter Lubricants
(→ Page 11).

Determination of silicon concentration and sulfur content in the fuel gas from gas
analysis
To determine the silicon or sulfur concentration, the measured concentrations or the sulfur content of the
individual compounds are multiplied by the Si or S mass fractions.
The result is based on the calorific value of the fuel gas and standardized at 10 kWh energy content (equals
1 m3 NTP. CH4).

Measured silicon share from the gas analysis (or sulfur concentration)
Concentration of silicon in sewage gas K Si 5.1 mg/m3 NTP
CH4 content of the sewage gas K CH4 65% by volume
Calorific value – sewage gas Hin 6.5 kWh/m3 NTP

Example: Calculated concentration of silicon limited to Hin = 10 kWh/m3NPT

Hin measured
KSi 10 (kW/m3i.N) = KSi measured x =
10 (kWh/m3NTP)

5.1 (mg Si/m3 6.5

x = 3.3 (mg Si/m3 NPT)
NTP) 10

TIM-ID: 0000081015 - 001

72 | General Information | A001072/06E 2022-03

 4.2 Series 4000 gas engine – Marine application
4.2.1 General
Important information
There is no warranty in case of impairments and / or damages (corrosion, contamination, etc.) that are
caused by gases or substances whose existence was not known or agreed upon at the time of signing the
contract.
TIM-ID: 0000081018 - 001

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 73

 4.2.2 Requirements of fuel gas for marine applications
Requirements and boundary conditions for mtu gas engines in marine
applications
Designation Unit Limit value Note
Type of gas Natural gas Applies to natural gas H, other gases
are currently not approved.
Methane number -- ≥70: Engine configura- Adjustments may prove necessary
tion for standard water depending on model type, power and
content in intake air fuel consumption.
≥75: Engine configura- Observe the Operating Instructions
tion for high water con- (Technical data).
tent in intake air Consult with the manufacturer before
operating with lower values as a gas
analysis is required in such case.
Knock monitoring reduces engine
power.
Methane number calculated in ac-
cordance with DIN EN 16726.
Calorific value Hi,n kWh/m3 n 9.2 <Hi,n < 11.5 Consult the manufacturer before op-
erating with lower or higher limit val-
ues.
Wobbe index WI kWh/m3 n 11.77 <WI i,n <14.18 The Wobbe index is related to the cal-
i,n1), 2) orific value.
The Wobbe index values must be re-
spected.
Admissible rate of kWh/m3 n/min 0.067 Constant linear change necessary
calorific value with a frequency of 1/h
change1)
Gas density2) kg/m3n 0.73 to 0.84 The gas density can vary according to
the composition; for a specific gas
type it is constant.
When using gas from different gas
supply areas, the density may vary.
Minimum gas pres- bar(g) 1 Relevant for idle and low-load opera-
sure upstream of tion.
gas regulation unit Consult the specifications for the gas
train of the relevant project / engine
type.
Permissible range bar(g)<supscrpt /> 6.0...10.0 Consult the specifications for the gas
for gas pressure train of the relevant project / engine
before the gas train type.
for full engine pow-
TIM-ID: 0000081017 - 007

er and acceleration
capacity.
Gas pressure devi- bar ±0.5 The setting value for gas pressure up-
ation from setpoint stream of the gas train must not be
undershot.
Permissible change bar/s 0.3 Constant change rate for transient
speed of gas pres- and steady state engine condition.
sure upstream of
gas train

74 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 Designation Unit Limit value Note
Gas temperature °C 10…40 Condensation of water vapor at
<10 °C, thermal aging of NBR materi-
als (seals, diaphragms) and impact of
higher temperatures on elasticity.
Minimum temperatures also apply to
the starting sequence. Consult the
specifications for the gas train of the
relevant project / engine type. Con-
sult the manufacturer before operat-
ing with lower or higher tempera-
tures.
Admissible rate of K/min 10
gas temperature
change
Water: °C 0 At operating pressure.
dew point No water vapor condensation in pres-
sure and temperature range.
Gas must be dried if values are high-
er.
Value valid for whole gas temperature
range.
Oil vapors (HC with mg/m3 n <10 No condensation in lines carrying fuel
carbon number >5) gas and fuel gas-air mixture.
No formation of condensable oil
mists.
HC solvent vapors mg/m3 n 0 Analysis and consultation with manu-
facturer is required
Organically-bound mg/m3 n CH4 < 1.0 Analysis and consultation with manu-
silicon (e.g. hydro- facturer is required
silicons, siloxanes,
silicons)
Inorganically-bound mg/m3 n <5 With Si >5 mg/m3N based on 100%
silicon CH4 fuel gas content, wear products
must be taken into consideration dur-
ing the oil analysis.
Dust 3 – 10 µm mg/m3 n <5 DVGW worksheet G260
Dust <3 µm mg/m3 n Analysis Analysis required
Hydrogen sulphide mg/kg 7 DIN 51624
Total sulfur mg/kg 10 DIN 51624
Chlorine mg/m 3
n 10 3) Consult the manufacturer in case of
higher values and an analysis is re-
quired
TIM-ID: 0000081017 - 007

Fluorine mg/m3 n 53) Consult the manufacturer in case of

higher values and an analysis is re-
quired

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 75

 Designation Unit Limit value Note
Chlorine + fluorine mg/m 3
n 10 3) Consult the manufacturer in case of
higher values and an analysis is re-
quired
NH3 ppm 703) Consult the manufacturer in case of
higher values and an analysis is re-
quired

Table 47:
1) = Calorific value
The amount of heat which would be released by complete combustion of a given amount of gas in air,
whereby the pressure p at which the reaction takes place remains constant and all combustion prod-
ucts return to the same temperature t as that of the reactants. All these combustion products are in
gaseous form.
The standard enthalpy of calorific value and Wobbe index specified here are referenced to a tempera-
ture of 25 °C. Please note that reference temperatures of 15 °C are commonly used in US publica-
tions.
Base conversion to other reference temperatures on EN ISO 6976 or EN ISO 14912.
2) = Volumetric quantities are based on the standard state specified in DIN 1343. The standard state is
the reference state defined by standard temperature Tn = 273.15 K or tn = 0 °C and standard pres-
sure pn = 101325 or Pa = 1.01325 bar.
Please note that the standard enthalpy references for heating and calorific values and Wobbe index
are based on 15 °C in US publications and more recent standards such as DIN EN 16726, and that
volumetric quantities are defined by the standard temperature T0 = 288.15 K or t0 = 15 °C and stand-
ard pressure pn = 101325 or Pa = 1.01325 bar.
3) = A non-binding guideline when using oxidation catalysts. Analysis and consultation with Rolls-Royce
Solutions are required.
The limit values are based on a calorific value of 10 kWh/m3n . This corresponds to a reference to
fuels with 100 % by vol. methane, or the existence of other combustible components in the fuel with
the same energy equivalent and the same input of hazardous materials.

TIM-ID: 0000081017 - 007

76 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 4.2.3 Specifications for the medium in the gas piping leak chamber for marine
applications
General
IGF 5.5.2 stipulates that all piping bearing fuel gas routed in engine rooms complying with the "safe machi-
nery concept" shall feature a double-wall or jacketed design. This leak chamber surrounding the fuel piping
shall facilitate the detection of leaking fuel gas by means of a suitable medium and appropriate measuring
technology. The IGF code basically envisages two ways of accomplishing this:
1. Purging/ventilating the leak chamber with air
2. Pressurizing the chamber surrounding the fuel pipe with an inert gas at a higher pressure than that of the
fuel gas.
The gas system of the mtu marine engine is designed for operation in either of these scenarios. The gas train
itself can only be used in conjunction with the air purging concept. The media in the leak chamber surround-
ing the gas piping are specified as follows:

1. Air purging concept

Designation Unit Limit value Note
Medium type Air Intake from outside the vessel via a
separate air tract
Medium tempera- °C 0-50
ture at engine inlet
Humidity (abs) gwater/kgdry air 37.7
Saline content in ppm 50
intake air
Volumetric flow m3/h 11.5 - 30 The lower limit value is based on the
max. volume including gas train and
supply pipework. The lower limit val-
ue ensures the minimum air change
rate per hour. The upper limit value
should not be exceeded to avoid ex-
cessive pressure loss.

Table 48:

2. Pressurized inert gas concept

Designation Unit Limit value Note
Medium type Nitrogen Nitrogen from a generator or cylin-
ders
Medium tempera- °C 0-80
ture at engine inlet
Water content vol.‰ ≤ 50 Nitrogen value 2.8
TIM-ID: 0000076444 - 005

Nitrogen purity % by vol. ≥99.8 Nitrogen value 2.8

Oxygen content vol.‰ ≤100 Nitrogen value 2.8
Medium pressure bar (abs) < 11
range

A001072/06E 2022-03 | Series 4000 gas engine – Marine application | 77

 Designation Unit Limit value Note
Chamber volume m 3
N 0.079 - 0.095
on engine (excl.
gas train) (jacket-
ing)
Leakage gnitrogen/h 3-5 Facilitates specification of refilling
volume/intervals

Table 49:
Detailed information on integration in the gas system and design concepts for monitoring and arranging the
various components are provided in the Safety Concept, schematic drawings and installation specifications.

TIM-ID: 0000076444 - 005

78 | Series 4000 gas engine – Marine application | A001072/06E 2022-03

 4.3 Series 4000 gas engine – Generator application and engine-
generator set
4.3.1 General
Important information
There is no warranty in case of impairments and / or damages (corrosion, contamination, etc.) that are
caused by gases or substances whose existence was not known or agreed upon at the time of signing the
contract.
TIM-ID: 0000081018 - 001

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 79
 4.3.2 Natural gas – Requirements of the fuel gas
Requirements for fuel gas
Designation Unit Limit value Note
Type of gas Natural gas Applies to natural gas H, L and pre-
mining coal bed methane.
Other gases are currently not ap-
proved.
Methane number -/min. 5 Linear constant change with a fre-
change quency of max. 1/h
Calorific value Hi,n kWh/m³ NTP 8.0 < Hi,n < 11.0 Consultation with manufacturer re-
quired in case of lower and higher
values
Calorific value devi- % ± 5** Consultation with manufacturer re-
ation from the set- quired for higher values
ting value
Admissible change %/min. 1.0 Linear constant change necessary
rate of calorific val- with a frequency of maximum 1/h
ue in relation to set
value
Density of gas kg/m³ NTP 0.73 to 0.84 The density of the gas can fluctuate
in accordance with the composition;
it is constant for a certain type of
gas.
When using gas from different gas
supply areas, the density may vary.
When changing to a different gas sup-
plier it may be necessary to adjust
the mixture control.
Gas pressure devi- % ±5
ation from the set-
ting value
Admissible gas mbar/min. 1 Constant change required
pressure change
rate
* = For engines with exhaust aftertreatment and/or exhaust gas heat recovery, lower limit values
may apply. When using oxidation catalytic converters, analysis and consultation with Rolls-Royce
Solutions are required.
** = For the optional operating mode "Energy balancing mode with quick-start feature 120 seconds*,
a limit value of ± 3 % from the setting applies.
TIM-ID: 0000051849 - 006

80 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Designation Unit Limit value Note
Gas temperature °C If there is a danger of undershooting
Natural gas from 5 < T < 45 the dew point, the gas temperature
the public gas sup- must be increased.
ply grid In case of deviating temperatures,
there is a danger of thermal aging of
NBR materials (seals, diaphragms)
and impact on elasticity.
Certain pressure and calorific value
combinations may restrict the tem-
Natural gas from 15 < T < 45 perature range. This can be compen-
LNG evaporator sated by pressure adjustment to
plants guarantee operation at rated load
over the complete temperature
range.
On plants with LNG operation, the
permissible temperature range must
be coordinated project-specifically.
The gas evaporation system design
must be analyzed on the part of Rolls-
Royce Solutions for this purpose.
Gas temperature °C ±9
deviation from the
setting value
Admissible rate of K/min. 0.3
gas temperature
change
Relative moisture % < 80 In the entire gas and mixture system
in gas in the per- no condensation is permitted.
missible tempera- No water vapor condensation in pres-
ture and pressure sure and temperature range.
range No condensation permitted in lines
Max. moisture in g/kg < 20 and containers carrying fuel gas and
gas, absolute fuel gas-air mixtures.
Oils / oil fumes mg/m³ NTP < 0.4 No condensation in lines carrying fuel
(HC with carbon gas and fuel gas-air mixture, nor for-
number >8) mation of condensible oil mists
Long-chain hydro- mewl % No information Consultation with Rolls-Royce Solu-
carbons (C6 - Cn) tions is required.
HC solvent vapors mg/m³ NTP 0 Consultation with manufacturer and
analysis necessary
Organically bound mg/m³ NTP < 1.0
silicon
Inorganically bound mg/m³ NTP <6 At Si > 5 mg/m³ NTP relative to
TIM-ID: 0000051849 - 006

silicon 100 % CH4 fuel gas content, wear prod-

ucts are to be taken note of in the oil
analysis
* = For engines with exhaust aftertreatment and/or exhaust gas heat recovery, lower limit values
may apply. When using oxidation catalytic converters, analysis and consultation with Rolls-Royce
Solutions are required.
** = For the optional operating mode "Energy balancing mode with quick-start feature 120 seconds*,
a limit value of ± 3 % from the setting applies.

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 81
 Designation Unit Limit value Note
Dust 3 to 10 µm mg/m³ NTP 5 DVGW worksheet G260
Dust must be removed in such a
manner that trouble-free operation of
standard-conformant, or standard de-
sign gas devices and gas equipment,
is ensured.
Dust< 3 µm mg/m³ NTP Technically free Dust < 3 µm must be evaluated
through a technical analysis, if neces-
sary appropriate special filters must
be used.
Total sulfur mg/m³ NTP 30 DVGW worksheet G260
Mercaptan sulfur mg/m³ NTP 6 DVGW worksheet G260
Hydrogen sulphide mg/m³ NTP 5 DVGW worksheet G260
H2S
Chlorine mg/m³ NTP 10* Consult the manufacturer in case of
higher values as analysis is necessary
Fluorine mg/m³ NTP 5* Consult the manufacturer in case of
higher values as analysis is necessary
Chlorine + fluorine mg/m³ NTP 10* Consult the manufacturer in case of
higher values as analysis is necessary
NH3 ppm 70* Consult the manufacturer in case of
higher values as analysis is necessary
* = For engines with exhaust aftertreatment and/or exhaust gas heat recovery, lower limit values
may apply. When using oxidation catalytic converters, analysis and consultation with Rolls-Royce
Solutions are required.
** = For the optional operating mode "Energy balancing mode with quick-start feature 120 seconds*,
a limit value of ± 3 % from the setting applies.
Table 50: Requirements and site conditions for natural gas fuel and the corresponding fuel supply
All listed limit values for pollutants (in ppm and mg/m3) are based on a calorific value of 10 kWh/m3 NTP.
This corresponds to a reference to fuels with 100 % by vol. methane, or the existence of other combustible
components in the fuel with the same energy equivalent and the same input of hazardous materials.
Example:
• Russian natural gas with a calorific value of 10 kWh/m3 NTP is used. The permissible value for total sulfur
in the gas thus corresponds exactly to the limit value specified in the table.
• When using a gas (e.g. East Hanover) with Hi,n = 8.15 kWh/m3 NPT, the permissible maximum value for
the total sulfur is calculated as follows:
Permissible total sulfur content = 30 mg/m³ NPT · (8.15 kWh/m3NPT : 10.0 kWh/m3 NPT) = 24.5 mg/
m³ NPT
TIM-ID: 0000051849 - 006

82 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 4.3.3 Biogas – Requirements for fuel gas
Biogas fuel requirements
Designation Unit Limit value Note
Type of gas Biogenic gases from
fermentation proc-
esses
Methane number -- ≥ 115 If undershot, danger of combustion knock.
Gas analysis and consultation with the fac-
tory required
Calorific value Hi,n kWh/m3 NTP 4.5 < Hi,n < 8.0 Consultation with manufacturer required in
case of lower and higher values
Calorific value devia- % ± 20 Consultation with manufacturer required for
tion from the setting higher values
value
Maximum rate of %/min. 1 <1/ h is permissible
change in the calorif- in normal operation
ic value in relation to
the setting value in
operation
Fast change in calo- %/min. <10.0 with a frequency of <1/ h is permissible
rific value during
starting and start-up
processes
Density of gas kg/m3 NTP 0.93 to 1.40 The gas density can fluctuate according to
the composition.
If there are changes to the main substrate
and/or significant changes in the mixing ra-
tio of the substrates, a gas analysis or, if
necessary, an adaptation of the mixture
control is required.
Gas pressure fluctua- % ± 10 This applies to the gas inlet at the gas con-
tion in relation to trol valve on the engine side
setting value
Admissible gas pres- mbar/min. 1 This applies to the gas inlet at the gas con-
sure change rate trol valve on the engine side
Gas temperature °C 5 < t < 45 Phase transitions in the fuel gas-air mixture
during engine operation are not permissible.
If there is a danger of undershooting the
dew point, the gas temperature must be in-
creased.
If there are deviating temperatures, there is
danger of thermal aging of NBR materials
TIM-ID: 0000051850 - 004

(seals, diaphragms) and the effects of

changes in elasticity at higher tempera-
tures.
The limit values apply to the gas inlet at the
gas control valve on the engine side
* = These values are recommended values for series 4000 engines, for gensets with exhaust after-
treatment, lower limit values can apply.
** = lower values apply to the 20V4000L32FB engine. Consultation with the factory is required.

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 83
 Designation Unit Limit value Note
Gas temperature de- °C ± 15 This applies to the gas inlet at the gas con-
viation from the set- trol valve on the engine side
ting value
Permissible change K/min. 0.3 This applies to the gas inlet at the gas con-
speed of trol valve on the engine side
Gas temperature
Relative gas humidity % < 80 In the entire gas and mixture system no
in the permissible condensation is permitted
temperature and No water vapor condensation in pressure
pressure range and temperature range.
g/kg <28 No condensation permitted in lines and con-
Max. moisture in gas, tainers carrying fuel gas and fuel gas-air
absolute mixtures.
At higher values or if there is a danger of
condensation in the operating range of pres-
sure and temperature, gas drying must be
provided.
Phase transitions in the fuel gas and air mix-
ture are inadmissible during engine opera-
tion in the pressure and temperature range;
gas drying is to be provided in case of high-
er values.
Oils / oil fumes mg/m3 NTP < 0.4 No condensation in lines carrying fuel gas
and fuel gas-air mixture, nor formation of
condensable oil mists.
HC solvent vapors mg/m3 NTP 0
Silicon from organic 3
mg/m NTP < 4* At Si > 2 mg/m3 NPT based on 100 % CH4
compounds fuel gas content, wear products must be
noted in the oil analysis.
Inorganically-bound mg/3 NTP < 2*
silicon
Dust 3 to 10 µm mg/m3 NTP 5 DVGW worksheet G260
Dust< 3 µm Technically free Dust must be removed in such a manner
mg/m3 NTP
that trouble-free operation of standard-con-
formant, or standard design gas devices and
gas equipment, is ensured.
Dust < 3 µm must be evaluated through a
technical analysis, if necessary appropriate
special filters must be used.
Silicon from organic mg/m3 NTP 6*
and inorganic com-
pounds
Total sulfur mg/m3 NTP 800* / **
TIM-ID: 0000051850 - 004

Mercaptan sulfur mg/m3 NTP 4*

Hydrogen sulphide 3
mg/m NTP 850*
H2S
Total of all chlorine mg/m3 NTP ≤ 40*
and fluorine com-
pounds
* = These values are recommended values for series 4000 engines, for gensets with exhaust after-
treatment, lower limit values can apply.
** = lower values apply to the 20V4000L32FB engine. Consultation with the factory is required.

84 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 Designation Unit Limit value Note
Chlorine 3
mg/m NTP ≤ 40* Consult the manufacturer in case of higher
values as analysis is necessary
Fluorine ≤ 20* Consult the manufacturer in case of higher
values as analysis is necessary
NH3 ppm 70* Consult the manufacturer in case of higher
values as analysis is necessary
* = These values are recommended values for series 4000 engines, for gensets with exhaust after-
treatment, lower limit values can apply.
** = lower values apply to the 20V4000L32FB engine. Consultation with the factory is required.
Table 51: Requirements and site conditions for biogas fuel and the corresponding fuel supply
When using the series 4000 in gensets, with and without exhaust heat coupling and/or exhaust aftertreat-
ment systems, the respective instructions provided by the engine-generator set manufacturer must be com-
plied with.

Requirements of the fuel "low-pollutant biogas"

The following limit values define "low-pollutant biogas". All other limit values for low-polluted biogas corre-
spond to the general limit values for biogas (→ Table 51).
Designation Unit Limit value Note
Silicon from organic 3
mg/m NTP < 1* At Si > 2 mg/m3 NPT based on 100 % CH4
compounds fuel gas content, wear products must be
noted in the oil analysis.
Inorganically-bound mg/3 NTP < 0.5*
silicon
Silicon from organic mg/m3 NTP 1.5*
and inorganic com-
pounds
Total sulfur mg/m3 NTP 140*
Mercaptan sulfur mg/m3 NTP 1*
Hydrogen sulphide 3
mg/m NTP 150*
H2S
Total of all chlorine mg/m3 NTP ≤ 8*
and fluorine com-
pounds
Chlorine mg/m3 NTP ≤ 8* Consult the manufacturer in case of higher
values as analysis is necessary
Fluorine ≤ 4* Consult the manufacturer in case of higher
values as analysis is necessary
NH3 ppm 14* Consult the manufacturer in case of higher
values as analysis is necessary
TIM-ID: 0000051850 - 004

* = These values are non-binding recommended values for Series 4000 engines, for gensets with ex-
haust aftertreatment, lower limit values can apply (→ Table 53).
Table 52: Requirements and site conditions for low-pollutant biogas fuel and the corresponding fuel supply
All listed limit values for pollutants (in ppm and mg/m3) are based on a calorific value of 10 kWh/m3 NTP.
This corresponds to a reference to fuels with 100 % by vol. methane, or the existence of other combustible
components in the fuel with the same energy equivalent and the same input of hazardous materials.

A001072/06E 2022-03 | Series 4000 gas engine – Generator application and engine-generator se... | 85
 Example:
• Russian natural gas with a calorific value of 10 kWh/m3 NTP is used. The permissible value for total sulfur
in the gas thus corresponds exactly to the limit value specified in the table.
• When using a gas (e.g. East Hanover) with Hi,n = 8.15 kWh/m3 NPT, the permissible maximum value for
the total sulfur is calculated as follows:
Permissible total sulfur content = 30 mg/m³ NPT · (8.15 kWh/m3NPT : 10.0 kWh/m3 NPT) = 24.5 mg/
m³ NPT

Pollutant concentration in fuel (with exhaust aftertreatment / exhaust gas heat

recovery)
Depending on the application, the following maximum permissible pollutant concentrations in the fuel must
be observed:
Oxidation catalyst / exhaust gas heat recovery
Without* / With / With /
Without 120 °C to Without
Designation Unit 180 °C
Sum of all sulfur compounds (cal- mg/m3 NTP 800 20 200
culated as S)
Hydrogen sulfide (H2S) ppm 550 7 70
Sum total of all chlorine com- mg /m3 NTP 40 0.5 0.5
pounds (calculated as CI)
Sum total of all fluorine com- mg /m3 NTP 40 0.5 0.5
pounds (calculated as F)
Total of all silicon compounds (cal- mg /m3 NTP 5 0 0
culated as Si)
Ammonia (NH3) ppm 30 30 30
Heavy metals (Pb, Hg, As, Sb, Cd) µg/m3 NTP Upon request 10 10
*= for "low-pollutant biogas", lower values apply accordingly (→ Table 52).
Table 53: Pollutant concentration in the fuel

TIM-ID: 0000051850 - 004

86 | Series 4000 gas engine – Generator application and engine-generator se... | A001072/06E 2022-03
 4.4 Series 400 gas engine – Engine-generator set
4.4.1 Natural gas – Fuel values
Fuel specifications to be complied with
The following fuel values must be observed at the inlet to the gas train (scope of supply of Rolls-Royce Solu-
tions):

Designation Unit Limit value

Minimum methane number
See Technical Description
Minimum calorific value
Rate of change, calorific value % per min <1
Rate of change, methane number Change in MN per min <5
Minimum gas flow pressure (overpressure) mbar < 20
Maximum gas flow pressure (overpressure) mbar < 50
Max. gas pressure variation (brief control fluctuation) mbar ±5
Max. rate of change of gas pressure mbar/s <1
Gas temperature °C 5 to 45
Max. water vapor content % by vol. < 0.5
Dust particle size > 3 µm mg/m3NPT <5
Oily constituents mg/m3NPT < 0.4

Table 54: Fuel specifications to be complied with

A max. total of 30 mg/m3NPT and, for brief periods, 150 mg/m3NPT, are permissible, but otherwise no cor-
rosive constituents may be present (analogous to DVGW Sheet G 260).

Important: The supplied gas filter (mesh size: 50 µm) fitted at the inlet of the gas train does not ensure com-
pliance with the dust limit value specified above and is used solely to protect the gas fittings.
TIM-ID: 0000053740 - 005

A001072/06E 2022-03 | Series 400 gas engine – Engine-generator set | 87

 4.4.2 Biogas – Fuel values
It is not possible to avoid variations in gas quality for biogas, sewage gas and landfill gas, the same applies to
harmful impurities.
In order to allow trouble-free operation and avoid damage, however, certain limit values have to be complied
with.
If it turns out during commissioning that the quality requirement for the fuel is not met, Rolls-Royce Solutions
reserves the right to charge for the aborted commissioning procedure.
Compliance with the emission and consumption values specified in the data sheet applies only to the speci-
fied reference gas compositions for biogas, sewage gas and landfill gas. The CO2 / CH4 volume ratio is of
importance here.
Important
The listed constituents / limit values listed are relevant for biogas engines. Other constituents / limit val-
ues are not permitted.

Fuel specifications to be complied with

The following fuel values must be observed at the inlet to the gas train (scope of supply of Rolls-Royce Solu-
tions):
Designation Unit Limit value
Minimum methane number
See Technical Description
Minimum calorific value
Rate of change, calorific value % per min 1
Rate of change, methane number Change in MN per min 5
CO2 / CH4 volume ratio - ≤ 0.65
Methane content, moist % by vol. See techn. data
Minimum gas flow pressure (overpressure) mbar 30
Maximum gas flow pressure (overpressure) mbar 50
Max. gas pressure variation (brief control fluctuation) mbar ±5
Max. rate of change of gas pressure mbar/s 1
Max. gas temperature (no derating) °C 35
Max. oxygen content % by vol. 2
Max. water vapor content % by vol. 3.1
Maximum temperature of cooled gas °C < 25
Dust particle size > 3 µm 3
mg/m NPT 5
Oily constituents 3
mg/m NPT 0.4

Table 55: Fuel specifications to be complied with

TIM-ID: 0000053741 - 007

CAUTION: The supplied gas filter (mesh size: 50 µm) fitted at the inlet of the gas train does not ensure com-
pliance with the dust limit value specified above and is used solely to protect the gas fittings.

88 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 4.4.3 Harmful impurities (pollutants)
The following application-dependent maximum limits for permissible pollutant concentrations in the fuel are
to be complied with:
Oxidation catalyst / exhaust gas heat recovery
With With With With
Without / EMK* / EMK* / SRK** / SRK** /
180 °C / Without 120 °C / Without 180 °C Without
180 °C
Biogas low-pol-
20 mg/m3 NTP 30 mg/m3 NTP
lutant
HCHO HCHO
Designation Unit biogas
Sum total of all sulfur 1200 140 20 200 70 140
compounds (S) mg/m3 NPT
Corresponding hydrogen 840 50 14 140 50 100
sulphide (H2S) ppm
Sum total of all chlorine 100 8 0.5 0.5 0.5 0.5
compounds (CI) mg/m3 NPT
Sum total of all fluorine 50 8 0.5 0.5 0.5 0.5
compounds (F) mg/m3 NPT
Sum total of all silicon 5 4 0 0 0 0
compounds (Si) mg/m3 NPT
Ammonia (NH3) ppm 60 14 60 60 60 60
Heavy metals (Pb, Hg, As, upon re- upon re- 10 10 10 10
Sb, Cd) µg/m3 NPT quest quest
* EMK = noble-metal catalytic converter
** SRK = sulfur-resistant catalytic converter
Table 56: Pollutant concentration in the fuel
All listed limit values for pollutants (in ppm and mg/m3) are based on a calorific value of 10 kWh/m3 NTP.
This corresponds to a reference to fuels with 100 % by vol. methane, or the existence of other combustible
components in the fuel with the same energy equivalent and the same input of hazardous materials.
Example:
• Russian natural gas with a calorific value of 10 kWh/m3 NTP is used. The permissible value for total sulfur
in the gas thus corresponds exactly to the limit value specified in the table.
• When using a gas (e.g. East Hanover) with Hi,n = 8.15 kWh/m3 NPT, the permissible maximum value for
the total sulfur is calculated as follows:
Permissible total sulfur content = 30 mg/m³ NPT · (8.15 kWh/m3NPT : 10.0 kWh/m3 NPT) = 24.5 mg/
m³ NPT
If the quality of the raw gas exceeds the appropriate limit value for sulfur, a gas desulfurization system, de-
signed according to the quality of gas in the system, has to be installed.
TIM-ID: 0000075182 - 005

With the special sulfur-resistant Rolls-Royce Solutions oxididation catalytic converter, operation without fine
desulfurization is permissible as long as the specified limit value for sulfur in the fuel is complied with.
In the case of active exhaust gas heat utilization, if limit values are exceeded during operation there will be
an increased build-up of corrosive deposits. Damage caused by these deposits can result in total failure of
the components. Earlier cleaning of the exhaust gas heat exchanger is therefore necessary.
Due to potential fluctuations in the sulfur content in practice, Rolls-Royce Solutions is unable to offer any
guarantees regarding the cleaning intervals.

A001072/06E 2022-03 | Series 400 gas engine – Engine-generator set | 89

 Concerning operation with the oxidizing catalytic converter without exhaust gas heat utilization, the exhaust
gas temperature at the exhaust gas system opening must definitely be above 300 °C. If necessary, the ex-
haust pipe must be insulated.

TIM-ID: 0000075182 - 005

90 | Series 400 gas engine – Engine-generator set | A001072/06E 2022-03

 4.5 Series 500 Gas Engine - Engine-Generator Set
4.5.1 Gas types
As the elements of fuel gases, in part, vary considerably, a classification of the gases based on certain prop-
erties and gas composition is necessary. A classification is carried out here based on their calorific value.
Parameters Symbol Limit Unit Remarks
Calorific value Hi,N <5 kWh / Nm³ Biogas operation requires
< 483.1 BTU/ft³ consultation with Rolls-
Royce Solutions
>5 kWh / Nm³ Biogas operation
> 483.1 BTU/ft³
> 10 kWh / Nm³ Natural gas operation
> 966.2 BTU/ft³

Table 57: Subdivision of fuel gases

The classification based on the calorific value provides an initial insight into whether the fuel gas can poten-
tially be used. The following (→ Table 58) provides an overview of which main elements are contained in the
respective fuel gases independently of their quantitative share.
Element Symbol Natural gas Biogas/sewage
gas/landfill gas
Methane CH4 X X
Ethane C2H6 X
Propane C3H8 X
Butane C4H10 X
Pentane C5H12 X
Hexane C6H14 X
Carbon Monoxide CO X
Carbon dioxide CO2 X X
Hydrogen H2 X
Nitrogen N2 X X
Oxygen O2 X

Table 58: Main elements of fuel gases

For gas secondary substances that are not named in this table nor in table (→ Page 92) consultation with
Rolls-Royce Solutions is required.
For biogas, make sure that gas segregation has not occurred during extended out-of-service periods or ex-
tended periods of gas storage.
TIM-ID: 0000092005 - 004

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 91

 4.5.2 Minimum requirements of gas composition
The following table provides information on the minimum requirements of the gas quality. The gas operating
data must also be observed (→ Page 93).
In addition, special components, e.g. a catalytic converter, may require deviating limit values in certain cir-
cumstances (→ Page 95).
Important
Continuous observance of the minimum gas requirements must be guaranteed by the customer!

The large number of possible fuel gases and the different compositions necessitate a gas-dependent analysis
of the gas quality limit values. For this purpose, Rolls-Royce Solutions requires a conversion of the gas analy-
sis values based on the calorific value, see (→ Page 94).
Parameters Symbol Limit Unit Remarks
Methane Number MN see Technical data Methane number requirement depend-
sheet ing on engine configuration. For exact
information, refer to the Technical data
sheet of the engine.
Chlorine Cl <8 mg / kWh Chlorine is present as a volatile com-
lb / BTU pound.
< 5.169 x10-9
Fluorine F <4 mg / kWh Fluorine is present as a volatile com-
-9 lb / BTU pound.
< 2.584 x10
Total chlorine + Σ (Cl, F) <8 mg / kWh
fluorine lb / BTU
< 5.169 x10-9
Dust content < 5 <1 mg / kWh
µm lb / BTU
< 0.646 x10-9
Oil vapor < 0.02 mg / kWh No condensation must form in the in-
-12 lb / BTU take tract.
< 12.9 x10
Solvents in com- VOC < 2.5 mg / kWh
bustion air lb / BTU
< 1.62 x10-9
Total silicon Σ Si < 0.2 mg / kWh High fluctuation in the gas. Oil analysis
-9 lb / BTU provides more exact information.
< 0.129 x10
Total sulfur ΣS < 40 mg / kWh Sulfur share from hydrogen sulfide
-9 lb / BTU must be taken into consideration via
< 25.83 x10
the molar masses with total sulfur.
Hydrogen sulfide H 2S < 42.4 mg / kWh
< 27.38 x10-9 lb / BTU
Ammonia NH3 <3 mg / kWh
TIM-ID: 0000092006 - 004

< 1.938 x10 -9 lb / BTU

Tar CxHyRz < 6.5 mg / kWh Only with syngas
lb / BTU Condensing must not take place in
< 4.2 x10-9
gas-carrying components. It may be
necessary to install a gas reheating
system.

Table 59: Permissible limit values for gas components

Deviations from the limit values or the use of further constituents not listed here only after consultation with
Rolls-Royce Solutions.

92 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 4.5.3 Gas operating data
Parameters Limit Unit Remarks
Rate of gas pressure change <1 mbar / 2 s
< 0.0145 psi / 2 s
Calorific value rate of change Hi <1 % / 30 s
Rate of change, methane number < 10 MN / min
Gas flow pressure at rated load for natural 20 – 70 mbar At inlet to gas regulating unit
gas operation 0.29 – 1.015 psi
Gas flow pressure at rated load for biogas 30 – 70 mbar At inlet to gas regulating unit
operation 0.4351 – psi
1.015
Max. assured gas pressure 500 mbar
7.25 psi
Temperature of the gas mixture before gas 10 – 30 °C
mixer TG 50 – 86 °F
Relative humidity φ < 60 % No condensation must form
in the intake tract and the
gas regulating unit.

Table 60: General boundary conditions for fuel gas

TIM-ID: 0000092018 - 003

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 93

 4.5.4 Conversion of limit values from gas analysis
The large number of possible fuel gases and the associated, in part widely varying, compositions necessitate
a dynamic analysis of the gas quality limit values.
For this purpose, Rolls-Royce Solutions requires a conversion of the gas analysis values depending on the
calorific value based on kWh / Nm³ (BTU / ft³).
The following is an example of the calculation.
Givens: Calorific value from gas analysis Hi,N 1.5 kWh / m³
Chlorine from gas analysis Cl 10 mg/m³
Fluorine from gas analysis F 5 mg/m³
Plant without catalytic converter
First, the measured values (MV) are converted on the basis of the calorific value Hi,N to a comparative value
(CV). This is then compared with the matching limit value (LV):
MVCl 10 mg/m³
CVCl = = = 6.6 mg/kWh < LVCl = 8 mg/kWh
HiN 1.5 kWh / m³
→ OK

MVF 5 mg/m³
CVF = = = 3.3 mg/kWh < LVF = 4 mg/kWh
HiN 1.5 kWh / m³
→ OK
The simultaneous presence of chlorine and fluorine means that a further limit value must be taken into con-
sideration:
CVCl, F = CVCl + CVF = 6.6 mg/kWh + 3.3 mg/kWh = 9.9 mg/kWh > LVCl = 8 mg/kWh
→ not OK

Important
In part, the gas composition from the gas analysis is expressed in ppm (parts per million). To make a com-
parison with the limit values possible, an intermediate conversion step is required. For this purpose, the
respective density under normal conditions is used in accordance with the following equation:
Measured value [mg/m³norm] = measured element volume [ppm] x densitynorm [kg/m³ norm]
TIM-ID: 0000092020 - 002

94 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 4.5.5 Special limit values
Deviations from the specified limit values or the use of further constituents not listed here only after consul-
tation with Rolls-Royce Solutions.

Permissible limit values for gas components with use of catalytic converter
With the use of a catalytic converter, the limit values become stricter as follows:
Parameter/catalytic converter toxin Symbol Limit Unit
Hydrogen sulfide H2S < 1.52 mg / kWh
< 0.982 x10-9 lb / BTU
Sulfur S <1 mg / kWh
< 0.646 x10 -9 lb / BTU
Ammonia NH3 <6 mg / kWh
< 3.877 x10-9 lb / BTU
Arsenic As < 0.2 µg / kWh
< 0.129 x10-12 lb / BTU
Mercury Hg < 0.2 µg / kWh
< 0.129 x10 -12 lb / BTU
Lead Pb < 0.4 µg / kWh
< 0.258 x10-12 lb / BTU
Cadmium Cd <2 µg / kWh
1.292 lb / BTU
Zinc Zn < 20 µg / kWh
< 12.92 x10-12 lb / BTU
Phosphor compounds and halogens P, F, Cl, Br, I, < 1 µg / kWh
At, Ts lb / BTU
< 0.646 x10-12
Silicon 0 µg / kWh
0 lb / BTU
Organic silicon - siloxane Si <30 µg / kWh
< 1.938 x10-11 lb / BTU
Sodium Na <2 µg / kWh
< 1.292 x10 -12 lb / BTU
Calcium Ca <2 µg / kWh
< 1.292 x10 -12 lb / BTU
TIM-ID: 0000092034 - 003

Bismuth Bi < 0.2 µg / kWh

< 0.129 x10-12 lb / BTU
Manganese Mn <2 µg / kWh
< 1.29 x10 -12 lb / BTU
Potassium K <2 µg / kWh
< 1.29 x10-12 lb / BTU
Antimony Sb < 0.2 µg / kWh
< 0.129 x10-12 lb / BTU

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 95

 Parameter/catalytic converter toxin Symbol Limit Unit
Chlorine Cl <2 µg / kWh
< 1.29 x10 -12 lb / BTU
Iron Fe <2 µg / kWh
< 1.29 x10-12 lb / BTU

Table 61: Permissible limit values for gas components with use of catalytic converter
Details not listed in the table remain unchanged.

Permissible limit values for gas components with use of activated carbon
With the use of an activated carbon filter, the limit values become stricter as follows:
Parameters Symbol Limit Unit Remarks
Oxygen max. O2 <3 % The development of explosive mixtures
must be prevented
Oxygen min. O2 > 0.5 % Follow manufacturer's instructions

Table 62: Permissible limit values for gas components with use of activated carbon
Details not listed in the table remain unchanged.

TIM-ID: 0000092034 - 003

96 | Series 500 Gas Engine - Engine-Generator Set | A001072/06E 2022-03

 4.5.6 Operational malfunctions due to condensate in the fuel gas
Operational malfunctions caused by insufficient freedom from condensate in the provided fuel gases shall
not be covered by the warranty.

Consequences of condensate in the fuel gas

Condensate contained in the power gas (e.g. with the lube oil of the gas compressor) can form an acidic
compound/emulsion. Among other things, this can result in the following:
• Corrosion (wear)
• TAN increase or TBN/ipH decrease in lube oil
• Carbon deposits on: Valves, piston ring grooves and chases

Prevention of malfunctions due to condensate in the power gas

• No vaporization due to cooling and/or pressure release.
• Mechanical separation (e.g. cyclone or separation filters) and removal of the condensate must only take
place with the engine no longer in operation. Following this, it is essential to seal the separation cock
again gastight.
• The gas line leading to the engine must be designed such that the gas does not cool any further and is
practically no longer depressurized through resistance or downstream pressure reducers. If necessary, in-
sulate the fuel gas line or possibly provide trace heating.
• As a certain amount of condensate can still enter the engine in spite of freedom from condensate at the
test valves, it is important that the condensate is largely free of acidifiers. To make sure of this, the pH
value of the aqueous solution accumulating at the condensate separators must be checked. The stronger
the acid the greater the harmful impact even with hardly detectable small amounts of condensate which
can nevertheless enter the engine with the gas.
• For biogas, with continuous operation at 50% power, or with exhaust gas cooling below 170 °C, or for
flexible energy balancing mode, continuous monitoring of the gas quality, in particular, H2S, is necessary.
The measured value must be documented via the MMC control system based on a 4-20 mA signal. The
signal can originate from a gas analysis by the customer or a specially installed H2S sensor. The gas sta-
tus before the machine must be monitored. This must be guaranteed with the selection of a suitable
measuring instrument with definition of the corresponding measuring points by the operating company.
TIM-ID: 0000092042 - 002

A001072/06E 2022-03 | Series 500 Gas Engine - Engine-Generator Set | 97

 5 Exhaust Gas Aftertreatment System
5.1 General
To reduce exhaust emissions on stoichiometric engines (lambda = 1, without excess air), 3-way catalytic con-
verters are used.
To reduce exhaust emissions due to incompletely burned combustion products on engine with lean operation
(operation with excess air), oxidation catalysts are used.
For additional reduction of NOx emissions with lean operation engines, SCR catalytic converters (selective
catalytic reduction) can be used. The reducing agent (urea solution with an urea concentration of 32.5 %) in
such catalysts reduces the nitrogen oxide emissions.
To guarantee the range of functions of the catalytic converters over a specific runtime, all specifications in
the Fluids and Lubricants Specifications (with regard to fuels, intake air, lube oils) must be observed.

TIM-ID: 0000079041 - 001

98 | Exhaust Gas Aftertreatment System | A001072/06E 2022-03

 5.2 NOx reducing agent AUS 32 for SCR exhaust gas
aftertreatment systems
To ensure efficient operation of the exhaust gas aftertreatment system, compliance of the reducing agent
with the quality requirements stipulated in DIN 70070 / ISO 222 41-1 is mandatory.
In Europe, this reducing agent is often offered under the brand name “AdBlue”.
The test methods for determining the quality and characteristics of the reducing agent are specified in the
standards DIN 70071 / ISO 222 41-2. The following table (→ Table 63) shows the quality characteristics of
the reducing agent together with the associated test methods (extract from ISO 222 41-1).
Important
SCR systems from Rolls-Royce Solutions are usually designed for a concentration of 32.5% urea. The use of
NOx reducing agent with other urea concentrations (AUS 40, AUS 48) requires a different design of the
dosing systems. Systems with the corresponding design must be run with the appropriately adapted con-
centration.
The purity requirements of the reducing agent then comply with the standards for AUS 32.

Important
The use of antifreeze additives for AUS 32, or winter urea, is generally not approved.

Quality features and test procedures for the reducing agent

Unit Test method ISO Limit values
Urea content by weight % 22241–2 Annex B 31.8 to 33.2
Spec. grav. at 20 °C kg/m3 3675 1087.0 to 1092.0
12185
Refractive index at 20 °C 22241–2 Annex C 1.3817 to 1.3840
Alkalinity as NH3 by weight % 22241–2 Annex D Max. 0.2
Biuret content by weight % 22241–2 Annex E Max. 0.3
Aldehyde content mg/kg 22241–2 Annex F Max. 5
Non-soluble constituents mg/kg 22241–2 Annex G Max. 20
Phosphate content as mg/kg 22241–2 Annex B Max. 0.5
P04
Metal contents 22241–2 Annex I
Calcium mg/kg Max. 0.5
Iron mg/kg Max. 0.5
Copper mg/kg Max. 0.2
Zinc mg/kg Max. 0.2
Chrome mg/kg Max. 0.2
Nickel mg/kg Max. 0.2
TIM-ID: 0000079042 - 004

Aluminum mg/kg Max. 0.5

Magnesium mg/kg Max. 0.5
Sodium mg/kg Max. 0.5
Potassium mg/kg Max. 0.5
Identity Identical with the refer-
ence sample

Table 63: Quality features and test procedures for the reducing agent

A001072/06E 2022-03 | Exhaust Gas Aftertreatment System | 99

 Storage of reducing agent
Information on storage/packaging/transport as well as suitable/unsuitable materials in the reducing agent
circuit can be obtained in the standard ISO 222 41-3. Also observe the manufacturer's specifications in this
regard.
Avoid direct sunlight because it promotes the occurrence of microorganisms and the decomposition of the
reducing agent.
Where possible, store and transport the reducing agent AUS 32 between -5 and +25 °C to prevent loss in
quality. Long storage periods at temperatures above 25 °C can lead to destruction of the reducing agent.
Max. constant storage temperature [°C] Min. durability [months]
≤10 36
≤25 18
≤ 30 12
≤35 6
>35 Check each batch prior to use

Table 64: Storage temperature of reducing agent

Important
The reducing agent crystallizes at -11 °C.

TIM-ID: 0000079042 - 004

100 | Exhaust Gas Aftertreatment System | A001072/06E 2022-03

 5.3 Exhaust condensate
Important information
Ensure that used fluids and lubricants are collected in sufficiently large collecting containers. Dispose of
fluids and lubricants in accordance with the applicable national specifications. Do not burn used oil or dis-
pose of in fuel tank.

When fuel is burned in the engine, nitrogen oxides NOx are created in addition to carbon dioxide and water
vapor. These transform into nitric acid in the downstream components in the presence of condensed water.
Other inorganic and organic acids, e.g. sulfuric acid or sulfurous acid, can likewise be created depending on
the fuel composition. Condensate samples therefore display a lightly pungent smell and dissolved iron as a
corrosion product. The hydrogen ion concentration, i.e. the pH value of such condensate samples, is usually
in the strong to weak acid range of pH = approx. 0.5 to 4.
The water dew point of the exhaust gas depends on the composition of the fuel gas used as well as the air
ratio at which the engine is operated. The water dew point is approx. 50 °C (lean engines) up to 80 °C (lamb-
da = 1). Condensate starts to form, depending on the acid-forming constituent, at exhaust temperatures be-
low approx. 170 °C (acid dew point).
Theoretically, 1.5 kg condensate can be created from 1 m3 NTP of natural gas. When exhaust gas is cooled
down to temperatures of approx. 100 °C, significant quantities of condensate only form during start-up pro-
cedures. When exhaust gas temperatures are further cooled (below T = approx. 80 °C), condensate starts to
accumulate continuously.
To limit condensate formation as much as possible (in the exhaust gas heat exchanger or in the downstream
exhaust silencer), you should guarantee the following with gensets with exhaust cooling:
• In the exhaust gas heat exchanger, never cool the exhaust gas temperatures below 110 °C
• Ensure exhaust lines are properly insulated
• Keep the ratio of the number of machine starts to operating hours as low as possible (average values low-
er than "one start" per four operating hours are recommended).
Where possible, do not merge condensate lines from different components before the siphon (or water seal)
because otherwise condensate would escape continuously during operation due to circulation in the conden-
sate line.
A free drain via a siphon (or water seal) must be provided for the condensate at a minimum height of 400
mm. In any case, however, the drain must have more than a 100 mm water column above the corresponding
maximum permissible exhaust back pressure of the engine. This prevents exhaust gas emerging from the
condensate line. The exhaust condensate should be neutralized in a neutralization plant before being dis-
charged into the sewerage system. An oil separator is additionally required.
The condensate drain line must be checked regularly during operation and safeguarded against freezing in
winter.
Exhaust condensate may only be discharged into the local sewage system without being treated after consul-
tation with the local waste water authority, and must not under any circumstances be discharged to atmos-
phere. Municipalities in Germany, or the authorities instructed by them, are obliged to remove accumulated
waste water which also contains condensate. Condensate can also be classified in the "Special waste" cate-
gory.
TIM-ID: 0000079045 - 001

A001072/06E 2022-03 | Exhaust Gas Aftertreatment System | 101

 6 Flushing and Cleaning Specifications for
Engine Coolant Circuits
6.1 Flushing and Cleaning Specifications for Series 400 and 4000
Engines
6.1.1 General information
In the course of time, sludge deposits from aging coolant additives can accumulate in the coolant circuits.
Reduced cooling capacity, clogged vent lines and drain points and dirty coolant level sight glasses can result.
Below-standard water quality or incorrect coolant preparation can also heavily contaminate the system.
If such conditions occur, the coolant circuit is to be flushed out with fresh water, repeatedly if necessary.
If these flushing sequences are insufficient or if the system is too heavily contaminated, the coolant circuit
and all affected parts must be cleaned.
Only clean, fresh water (no river or sea water) must be used for flushing.
Only products approved by Rolls-Royce Solutions or equivalent products at the specified concentrations may
be used for cleaning, see (→ Page 103). The specified cleaning procedure is to be complied with.
Immediately after flushing or cleaning, fill the coolant circuits with prepared engine coolant as stipulated in
the current Fluids and Lubricants Specifications. Otherwise there is a danger of corrosion!
Important
Fluids and lubricants (e.g. treated engine coolant), used flushing water, cleaning agents and cleaning solu-
tions can be hazardous materials. Certain regulations must be obeyed when handling, storing and disposing
of these substances.
These regulations are contained in the manufacturer's instructions, legal requirements and technical guide-
lines valid in the individual countries. Considerable differences can apply from country to country so that
no generally valid statement on the applicable regulations for fluids and lubricants etc. can be made in this
publication.
Users of the products named in these specifications are therefore obliged to inform themselves of the lo-
cally valid regulations. Rolls-Royce Solutions accepts no responsibility whatsoever for improper or illegal
use of the fluids and lubricants / cleaning agents which it has approved.

Important
Scrap oil heat exchangers from engines with bearing or piston seizures or friction damage.

Test equipment, auxiliary materials and fluids and lubricants

mtu test kit or electrical pH-value measuring instrument
Required auxiliary materials:
TIM-ID: 0000080702 - 004

• Compressed air
• Superheated steam
Required fluids and lubricants:
• Fresh water
• Prepared engine coolant

102 | Flushing and Cleaning Specifications for Engine Coolant Circuits | A001072/06E 2022-03
 6.1.2 Approved cleaning agents
Manufacturer Product name Working concentration Order no.
For coolant systems:
Kluthe Hakutex 111 1, 5) 2% by volume Liquid X00065751
Decorrdal 20-1 8) 10% by volume Liquid 7)

Hakupur 50-706-3 4) 2% by volume Liquid X00055629

For cooling circuit assemblies:
Henkel Bonderite C-AK FD 2) 1 to 10% by weight Powder 7)

Bonderite C-MC 2 to 10% by weight Powder 7)

11120 3)
Kluthe Hakutex 60 mtu 9) 100% by volume Liquid X00070585
(25 kg)
For coolant systems contaminated with bacteria, fungi or yeast (so-called system cleaners):
Vink Chemicals Grotan WS Plus 5) 0.15% by volume Liquid X00065326
(10 kg)
Grotanol SR2 6) 0.5% by volume Liquid X00069827
(10 kg)

Table 65:
1) 6)
For light lime deposits, light corrosion Bacteria contamination up to > 10 4, contamination
with fungi and yeast
2) 7)
For lime deposits containing oil and grease Not stocked by Rolls-Royce Solutions
3) 8)
Preferred for heavy lime deposits With serious corrosion; not permitted for alumi-
num materials
4) 9)
For oily and greasy residues. Not suitable for Solvent cold cleaner for oily and greasy residues
galvanized surfaces
5)
Bacteria contamination up to 10 4

Important
The technical data sheets and safety data sheets of the product must be observed!

The cleaning agents are available world-wide through the branches of the manufacturers or their trading part-
ners.
TIM-ID: 0000019197 - 017

A001072/06E 2022-03 | Flushing and Cleaning Specifications for Series 400 and 4000 Engines | 103
 6.1.3 Engine coolant circuits – Flushing

1. Drain engine coolant.

2. Measure the pH value of the freshwater using the mtu test kit or an electrical pH value measuring device.
3. Fill freshwater into the coolant circuit.
Important
Never pour cold water into a hot engine!

4. Preheat the engine, start it up and run until warm.

5. Run engine at increased speed for approx. 30 minutes.
6. Take flushing liquid sample at engine-coolant-sample extraction cock.
7. Shut down engine.
8. Drain flushing liquid.
9. Measure pH value of flushing liquid sample using the mtu test kit or electrical pH value measuring device and
compare with the pH value of the freshwater.
a) pH value difference < 1: Fill system with treated coolant and start engine.
b) pH value difference > 1: Fill with fresh flushing liquid and repeat flushing cycle.
c) If the pH value difference is still > 1 even after flushing 4 to 5 times the coolant circuit must be cleaned,
see (→ Page 105). The assemblies may also need cleaning, see (→ Page 106).
Important
Refer to the engine operating instructions for additional information.

TIM-ID: 0000037747 - 007

104 | Flushing and Cleaning Specifications for Series 400 and 4000 Engines | A001072/06E 2022-03
 6.1.4 Engine coolant circuits – Cleaning

1. Mix cleaner to the specified concentration with freshwater. Use warm freshwater (45 °C) if the engine is
warm.
2. Cleaning agents for coolant circuits are prepared in warm freshwater as a concentrated solution, see
(→ Page 103).
3. In the case of powdered products, stir until the cleaning agent is completely dissolved and without sediment.
4. Pour solution together with freshwater into coolant circuit.
5. Start engine and run until warm.
6. Select temperature and duration of residence time according to the specifications of the technical data
sheets of the manufacturer.
7. Shut down engine.
8. Drain off cleaning agents and flush the engine coolant circuit with fresh water.
9. Take flushing liquid sample at engine-coolant-sample extraction cock.
10. Measure pH value of flushing liquid sample using the mtu test kit or electrical pH value measuring device and
compare with the pH value of the freshwater.
a) pH value difference < 1: Fill system with treated coolant and start engine.
b) pH value difference > 1: Clean assemblies, see (→ Page 106).
Important
Refer to the engine operating instructions for additional information.
TIM-ID: 0000037713 - 009

A001072/06E 2022-03 | Flushing and Cleaning Specifications for Series 400 and 4000 Engines | 105
 6.1.5 Cleaning engine coolant circuit assemblies

1. Remove, disassemble and clean assemblies in the engine coolant circuit that are exposed to heavy sludge
deposits e.g. expansion tanks, preheating units, heat exchangers (coolant cooler, oil heat-exchanger, charge-
air cooler, charge-air preheater, fuel preheater etc.) and lower sections of pipework.
2. Before cleaning, examine degree of contamination on water sides.
3. In case of lime deposits that contain oil and grease, degrease the water side first.
4. Deposits in charge-air coolers caused by oil mist can be removed using Kluthe Hakutex 60.
5. Remove hard lime deposits with a decalcifying product. In the event of stubborn lime deposits, if necessary a
10% inhibited hydrochloric acid solution may have to be used.
6. Dissolve deposits on and in heat-exchanger elements in a heated cleaning bath. Observe the manufacturer's
specifications and use only approved detergents in the permissible concentration, see (→ Page 103)
Important
Deposits on the oil side can also be dissolved in a kerosene bath.
The dwell time in the cleaning bath depends on the type and degree of contamination, as well as the tem-
perature and activity of the bath.

7. Clean individual components such as housings, covers, pipes, sight glasses, heat-exchanger elements with
superheated steam, a nylon brush (soft) and a powerful water jet.
Important
In order to avoid damage:
Do not use hard or sharp-edged tools (steel brushes, scrapers, etc.) (oxide protective layer).
The pressure of the water jet must not be ≤ 60 bar (to avoid damage, e.g. of the cooler fins).

8. After cleaning, blow through the heat exchanger elements with low-pressure steam in the direction opposite
to operational flow, rinse with clear water (until pH-value difference is < 1) and blow dry with compressed or
hot air.
9. Check that all components are in perfect condition, repair or replace as necessary.
10. Flush oil and engine coolant sides of heat-exchanger elements with corrosion-inhibiting oil. This step may be
omitted if the heat exchanger is installed and taken into service immediately after cleaning.
11. After installing all assemblies, flush engine coolant circuit once, see (→ Page 29).
12. Check coolant system for leaks during initial operation of engine.
Important
For further information, see the Maintenance Manual for the engine in question.
TIM-ID: 0000037714 - 007

106 | Flushing and Cleaning Specifications for Series 400 and 4000 Engines | A001072/06E 2022-03
 6.1.6 Coolant circuits contaminated with bacteria, fungi or yeast
System cleaning
The system cleaner must flow a sufficiently long time through the complete cooling system to ensure effec-
tive cleaning and disinfection.
Therefore, the predefined amount of the approved system cleaner must be added to the contaminated cool-
ant in the system, see (→ Page 103). Use a circulating pump to provide continuous mixture flow through the
coolant system for at least 24 hours or max. 48 hours.

Flushing
When the coolant and system cleaner have been drained, the cooling circuit must be flushed with fresh wa-
ter. Flushing must be carried out until no more contaminants are visible and the flushing liquid has the same
pH-value as the fresh water used (max. pH-value difference < 1).

Refill
Before refilling the circuit, make sure the system is free of contaminants.
Refill must be performed directly after flushing to avoid the risk of corrosion!
TIM-ID: 0000019202 - 006

A001072/06E 2022-03 | Flushing and Cleaning Specifications for Series 400 and 4000 Engines | 107
 6.2 Flushing and Cleaning Specifications for Series 500 Engines
6.2.1 General information
Only clean, fresh water (no river or sea water) must be used for flushing.
Only the P3 Standard cleaning agents must be used for cleaning, see (→ Page 109). The specified cleaning
procedure is to be complied with.
Immediately after flushing or cleaning, fill the coolant circuits with prepared engine coolant as stipulated in
the current Fluids and Lubricants Specifications. Otherwise there is a danger of corrosion!
Important
Fluids and lubricants (e.g. treated engine coolant), used flushing water, cleaning agents and cleaning solu-
tions can be hazardous materials. Certain regulations must be obeyed when handling, storing and disposing
of these substances.
These regulations are contained in the manufacturer's instructions, legal requirements and technical guide-
lines valid in the individual countries. Considerable differences can apply from country to country so that
no generally valid statement on the applicable regulations for fluids and lubricants etc. can be made in this
publication.
Users of the products named in these specifications are therefore obliged to inform themselves of the lo-
cally valid regulations. Rolls-Royce Solutions accepts no responsibility whatsoever for improper or illegal
use of the fluids and lubricants / cleaning agents which it has approved.

Important
Scrap oil heat exchangers from engines with bearing or piston seizures or friction damage.

Test equipment, auxiliary materials and fluids and lubricants

mtu test kit or electrical pH-value measuring instrument
Required auxiliary materials:
• 2 x 200 l steel barrel
• Hose for bypass as plate-core heat exchanger
• Spare flushing barrel
• 1-10 or 1-5 softening cartridge for water conditioning
Required fluids and lubricants:
• Fresh water
TIM-ID: 0000094905 - 002

108 | Flushing and Cleaning Specifications for Series 500 Engines | A001072/06E 2022-03
 6.2.2 Approved cleaning agents
Approved cleaning agents
Cooling system cleaning agents: P3 Standard, non-foaming powder.
25% phosphoric acid cartridge.
Important
The technical data sheets and safety data sheets of the product must be observed!

The cleaning agents are available through the branches of the manufacturers or their trading partners.
TIM-ID: 0000094906 - 001

A001072/06E 2022-03 | Flushing and Cleaning Specifications for Series 500 Engines | 109
 6.2.3 Engine cooling system – Cleaning

Draining engine coolant

1. Connect fresh water hose on the thrust side of the engine coolant pump and connect to engine coolant
pump.
2. Connect hose with waste water hose to intake side of engine coolant pump and place in a barrel.
3. Drain old water-glycol mixture and dispose of in accordance with the manufacturer's specifications.
4. Remove plate-core heat exchanger and replace with a bypass.
5. If the plate-core heat exchanger is seriously contaminated (pressure loss > 500 mbar), remove it (see step
4). Replace the old plate-core heat exchanger with a cleaned or new plate-core heat exchanger.

Preflushing engine coolant circuit

Note: • Engine is not was started.
• Never pour cold water into a hot engine (> 60 °C)!
1. Preflush engine coolant circuit with fresh water.
2. Flush out coarse dirt particles.
3. Drain water.

Mixing in cleaning solution

Note: • Plant is filled with demineralized water.
• The water must be softened. For softening, a water conditioning cartridge must be cut in through which
the fresh water is directed.
• If hard water is used for flushing, there is a danger from a temperature of < 60 °C that limescale falls out
and irreparably clogs the heat exchanger.
1. Fill the mixing barrel until half full.
2. Provide a flushing barrel.
Note: • Do not allow the coolant pressure in the engine to exceed 1.5 bar.
• Regulate the pressure via the inlet and supply volume.
.
3. Allow the water from the plate-core heat exchanger in the engine circuit to drain via the hose into the barrel.
4. Extract water with electric pump out of barrel and add again to the engine circuit behind the plate-core heat
exchanger.
5. Start engine and run at 60% power up to operating temperature.
6. Add the P3 solution in steps via the flushing barrel until a pH value of approx. 13 is reached.
7. Run the CHP at 60% power for approx. one hour.
8. Switch off engine.
9. Drain P3 solution and replace with fresh, demineralized water until a pH value of 10 is reached.
10. Start the CHP.
11. Close all valves that lead to the flushing barrel.
12. Run the CHP at 60% power over night.
13. Pump off P3 solution.
14. Neutralize in the flushing barrel with 25% phosphoric acid until a pH value of 7 is reached.

Flushing out cleaning solution

TIM-ID: 0000094908 - 001

1. Flush out cleaning solution with the plant in operation.

2. Reflush with approx. 2 mᶟ water.

Refill
Note: If necessary, install plate-core heat exchanger.
1. Fill fresh water-glycol mixture.
2. Document pressure losses in the plant folder.

110 | Flushing and Cleaning Specifications for Series 500 Engines | A001072/06E 2022-03
 7 Inlet Air and Combustion Air
7.1 General information
Important
No corrosive compounds must penetrate the intake air.
The specified limit values must be observed because otherwise the warranty shall become void.

For operation in swimming pools or near refrigerating machines, note that even small traces of halogen com-
pounds in the supply air (intake air) can lead to corrosion on the following components:
• In the engine
• On peripheral components, e.g. electric motors
Cleaning agents can also contain aggressive substances that can cause corrosion.
In case of doubt, consult Rolls-Royce Solutions.
The intake air must not be supplied with desorption air or off-gases from thermochemical process without
prior consultation with Rolls-Royce Solutions.
The permissible temperature range with specification of the minimum and maximum temperature is stipulat-
ed in the technical data sheet of the engine / genset.

Limit values in the gas mixture

The gas mixture consists of air and fuel. The limit values in the gas mixture must not be exceeded
(→ Page 68).
The limit values in the gas mixture (in ppm) are clearly lower than the values specified for the fuel (usual-
ly lower by approx. factor 20).
TIM-ID: 0000051960 - 007

A001072/06E 2022-03 | Inlet Air and Combustion Air | 111

 7.2 Humidity
When operating gas engines in high air humidity conditions, there is a danger of condensation in the gas-air
mixture. This condensation can lead to damage, e.g. corrosion on parts that make contact with the mixture.
The dew point [°C] of the intake air is drawn on for assessing the permissible air humidity.
All gas engines from Rolls-Royce Solutions can be operated with intake air below a dew point of 20 °C. Oper-
ation with intake air above a dew point of 17.5 °C should therefore be restricted to < 200 operating hours
per year. A dew point temperature of the intake air above 21 °C is only permitted for specially designed
products or with project-specific adaptations.
Damage caused by operation with excessive air humidity shall be excluded from the warranty.

TIM-ID: 0000096234 - 002

112 | Inlet Air and Combustion Air | A001072/06E 2022-03

 7.3 Dust load
Dust deposits reduce the heat dissipation of surfaces and can therefore lead to thermal overload and prema-
ture failure of components. This affects not only the engine and generator but also other electrical operating
equipment.
To prevent harmful effects of dust, filters are used in various places and have to be replaced corresponding
to defined maintenance intervals or based on their condition.
The service life of the combustion air filters can be drawn on as an indicator of increased dust load because
the contaminated state of this filter is recorded via a measurement.
A shortened service life of these filters indicates an increased, impermissible dust load in the engine room
and technical measures for conditioning the engine room air / combustion air must be introduced to prevent
damage to the components and electrical operating equipment.
Damage caused by an increased dust load of the machine room air shall be excluded from the warranty.
Design of the combustion air filtration as a fine dust filter in accordance with ISO 16890 ePM1 50% (formerly
DIN EN 779 F7).
If filtration of the supply air to the engine room is necessary, with a general dust load we recommend pocket
filters in accordance with ISO 16890 ePM10 50% (formerly DIN EN 779 M5) where all particles of particle
class PM10 are at least 50% separated. In case of special project-specific dust loads, e.g. through coarse fiber
dust, sand load in desert areas or large amounts of fine-grained dust from mills, foundries or cement facto-
ries, the filtration must be designed for the prevailing particle load.
TIM-ID: 0000096196 - 001

A001072/06E 2022-03 | Inlet Air and Combustion Air | 113

 8 Heating Water
8.1 General information
Important
The specifications of Rolls-Royce Solutions with regard to conditioning / ventilation of the coolant circuits
must be observed.
The specified limit values must be observed because otherwise the warranty shall become void.

Important
Requirements for the quality of heating water above 100 °C apply when an exhaust heat exchanger has
been installed in the engine cooling circuit or the heating circuit.

Important
Adding sulfite is not allowed.
It is recommended to use WBcon 2347 as an alternative for the heating water circuit.
Please note that the product contains borates and sodium hydroxide, which are corrosive to materials such
as aluminum and brass.

Supplementary information
It is pointed out as a precaution that, in general, costs for foreseeable damage, e.g. by unsuitable water qual-
ity, are not covered by machine breakdown insurance either.
The term "Sum total, alkaline earths" refers to the content of hardness-forming, dissolved calcium and mag-
nesium salts. To convert to the former standard unit of measurement of "Total hardness", the following ap-
plies:
• 1 mol/m 3 = 5.6 dH
• The pH value is a measure of the acidity or alkalinity of a solution.
• pH = 7 neutral, < 7 acid, > 7 alkaline.
Important
Max. permissible fluctuation of the heating water inlet temperature: Max. 3 K / min.

TIM-ID: 0000051994 - 006

114 | Heating Water | A001072/06E 2022-03

 8.2 Information on heating water for Series 4000 and 400
Important
Adding sodium sulfite as binding agent for oxygen is not allowed.

Important
The base alkalization must occur with trisodium phosphate.

Requirements of heating water up to 100 °C

VDI Directive 2035 Sheet 1 (December 2005) and Sheet 2 (September 1998) is definitive. "Prevention of
damage by corrosion and scale formation in water heating installations" with the following guide values (see
also the corresponding explanations in the original):
General requirements Clear, colorless and free from
undissolved substances
pH value (25 °C) 8.0 to 9.0
Electric conductivity (25 °C) < 250 μS/cm
Sum total, alkaline earths Up to 1.5 mmol/l
Up to 8.4 °dH
Chlorides < 50 mg/l
Sulfates < 50 mg/l
Phosphates < 10
Oxygen content when using oxy- < 0.1 mg/l
gen binding agents
Iron < 0.2 mg/l

Table 66: Requirements of heating water up to 100 °C

If the upper limit values are not observed, the following measures are required:
• Against scale formation: Coolant conditioning (softening, complete demineralization, reverse osmosis) or
hardness stabilization (ST-DOS-H products)
• Against corrosion processes: Inhibition or oxygen binding (ST-DOS-H products)

Requirements imposed on heating water above 100 °C

The definitive specification is the VdTÜV Directive TCh 1466 governing the quality of water in heating instal-
lations which are operated with a supply temperature above 100 °C. The following guide values subsequently
apply for low-salt method of operation:
General requirements Clear, colorless and free from
undissolved substances
pH value (25 °C) 8.0 to 9.0 *
Electric conductivity (25 °C) 10 to < 250 μS/cm
TIM-ID: 0000051996 - 005

Sum total, alkaline earths < 0.02 mmol/l

< 0.10 °dH
Chlorides < 20 mg/l
Sulfates < 5 to 10 mg/l
Oxygen content < 0.05 mg/l
* Deviation from TCh 1466 (TÜV)

A001072/06E 2022-03 | Heating Water | 115

 General requirements Clear, colorless and free from
undissolved substances
Phosphatized 5 to 10 mg/l
Iron < 0.2 mg/l
* Deviation from TCh 1466 (TÜV)
Table 67: Requirements imposed on heating water above 100 °C
Measures against scale formation and corrosion processes:
• Against scale formation: Coolant conditioning (softening, complete demineralization, reverse osmosis) or
hardness stabilization (ST-DOS-H products)
• Against corrosion processes: Inhibition or oxygen binding (ST-DOS-H products)

TIM-ID: 0000051996 - 005

116 | Heating Water | A001072/06E 2022-03

 8.3 Information on Heating Water for Series 500 Engines
8.3.1 Water quality for heating water circuit Series 500
When topping up large volumes of supplementary water, or at least once a year, the water quality must be
checked by means of a water analysis. For water quality, see (→ Page 118).
If the specifications of these technical instructions are not observed, the operating company must commis-
sion a specialist company with the water conditioning.
Characteristic Unit Limit value
Appearance - Clear and of neutral odor, free of sediment and sus-
pended particles
pH value at 25 °C - 8.2 to 10.0
Electr. conductivity (at 25 °C) μS/cm < 250
Oxygen content O2 mg/l < 0.05
Total hardness * °dH < 0.3 (=0.05 mmol/l)
Chlorides mg/l < 10
Phosphate (PO4) mg/l 5 to 10
* If the total heating output of the heating system is less than 600 kW, higher values according to
VDI 2035, Sheet 1 can be tolerated
Table 68: Limit values for heating water circuit
TIM-ID: 0000092049 - 001

A001072/06E 2022-03 | Information on Heating Water for Series 500 Engines | 117
 8.3.2 Heating water – Water quality Series 500
Further information on observance of the water quality
• Operation with deionized water with a weak alkaline buffering is generally recommended. In particular,
with a pH value that has to be closely observed this prevents the self-alkalization effect. Furthermore, this
type of water conditioning removes further elements that have corrosive effects (e.g. chlorides).
• In general, corrosion effects are prevented by low conductivity of the heating water. A low-salt control
mode according to VDI 2035 is with a value < 100 μS/cm. The limit values for the heating water circuit
should be undershot (→ Page 117).
Important
Relevant rules and standards provide further information (DIN EN 12828, VDI 2035, VD-TÜV, Specification
Sheet 1466,…).

TIM-ID: 0000092051 - 001

118 | Information on Heating Water for Series 500 Engines | A001072/06E 2022-03
 9 Confirmation for Fluids and Lubricants
9.1 Confirmation by the operator of engine-generator sets
Important
The plant must not be put into operation without this confirmation.

Plant description:

Plant consisting of:

Factory / SAP no.:

Customer:

Operator:

Rolls-Royce Solutions project manager:

We hereby confirm that the quality of the fluids and lubricants (coolant, gas, lubricating oil, heating water,
etc., where applicable) conforms to the Fluids and Lubricants Specifications of Rolls-Royce Solutions.
Rolls-Royce Solutions does not provide any warranty for damage incurred as a result of deviating fluid and
lubricant quality.

City / date

Legally binding signature (customer)

TIM-ID: 0000051982 - 005

A001072/06E 2022-03 | Confirmation for Fluids and Lubricants | 119

 10 Revision Overview
10.1 Revision overview
Technical changes from version A001072/05 to version A001072/06

Changes
• Chapter 4.5: Series 500 gas engine – Engine-generator set
– Tables revised and corrected

TIM-ID: 0000098552 - 004

120 | Revision Overview | A001072/06E 2022-03

 11 Appendix A
11.1 List of abbreviations
Abbreviation Meaning Explanation
ASTM American Society for Testing and Materi- –
als
Bh Betriebsstunden Operating hours
BR Baureihe Series
BV Betriebsstoffvorschrift Fluids and Lubricants Specifications
DIN Deutsches Institut für Normung e. V. German national standards institute, at the
same time identifier of German standards (DIN
= "Deutsche Industrie-Norm”)
DVGW Deutsche Vereinigung des Gas- und German Federal Association for Gas and Water
Wasserfaches e.V.
EN Europäische Norm European standard
IP Institute of Petroleum –
ISO International Organization for Standardi- International umbrella organization for all na-
zation tional standardization institutes
MZ Methanzahl Methane number
SAE Society of Automotive Engineers U.S. standardization organization
ST-DOS-H Sicherheitsdatenblatt Safety data sheet
VDI Richtlinie, Normen Regeln und Stand- Guidelines, rules, and standards
ards
VdTÜV Technische Regeln Technical rules
Vol. Volumen Volume
TIM-ID: 0000075707 - 003

A001072/06E 2022-03 | Appendix A | 121

 11.2 Conversion table of SI units
SI unit US unit conversion
°C °F °F = °C*1.8+32
kWh BTU 1 BTU = 0.0002930711 kWh
3 3
kWh/m NTP BTU/ft 1 BTU/ft3 = 00.010349707 kWh/m3
kW kBTU/h 1 kBTU/h = 0.2928104 kW
kW bhp 1 bhp = 0.7457 kW
l gal 1 gal = 3.785412 liters
mm inch 1 inch = 25.4 mm
m ft 1 ft = 0.3048 m
m/s ft/s 1 ft/s = 0.3048 m/s
3 3
m NTP ft NTP ft3 = 0.02831685 m³ NTP
bar psi 1 psi = 0.06894757 bar
kg lb 1 lb = 0.4535924 kg

Table 69: Conversion table

TIM-ID: 0000053888 - 001

122 | Appendix A | A001072/06E 2022-03

 11.3 Contact person/Service partner
Service
The worldwide network of the sales organization with subsidiaries, sales offices, representatives and custom-
er service centers ensure fast and direct support on site and ensure the high availability of our products.

Local Support
Experienced and qualified specialists place their knowledge and expertise at your disposal.
For locally available support, go to the Internet site: http://www.mtu-solutions.com

24 h Hotline
With our 24 h hotline and high flexibility, we are your contact around the clock: during each operating phase,
preventive maintenance and corrective operations in case of a malfunction, for information on changes in
conditions of use and for supplying spare parts.
Your contact person in our Customer Assistance Center:
E-mail: [email protected]

Spare Parts Service

Quick, easy and correct identification of the spare part required for your system. The right spare part at the
right time at the right place.
With this aim in mind, we can call on a globally networked parts logistics system.
Your contact at Headquarters:
Germany:
• Tel: +49 821 74800
• Fax: +49 821 74802289
• E-mail: [email protected]
Worldwide:
• Tel: +49 7541 9077777
• Fax: +49 7541 9077778
• E-mail: [email protected]
TIM-ID: 0000002624 - 009

A001072/06E 2022-03 | Appendix A | 123

 12 Appendix B
12.1 Index
A Coolant
Antifreeze – Test kit 102, 108
– For cooling system containing light metals – Antifreeze
– Concentrates 56 – Concentrates for special applications 50, 60
– Ready mixtures 61 – Check 66
– For cooling systems free of light metals – Conditioning
– Concentrates 47 – Series 400 41
– Ready mixtures 51 – Series 4000 40
– Series 400 64 – Series 500 42
– Series 500 67 – Coolant without antifreeze
Applicability of the publication 5 – Concentrates for cooling systems containing light
Approved engine fluids and lubricants metal 44, 54
– Engine oils for Series 4000 15 – Ready mixtures for cooling systems containing
Approved fluids and lubricants light metal 55
– Engine oils for Series 400 20 – Ready mixtures for cooling systems free of light
– Engine oils for Series 500 26 metal 46
– Definition 30
B – Engine-generator set
Biogas – Series 4000 43, 53
– Main constituents 70 – Series 500 65, 67
– Requirements – Fresh water requirements
– Series 400 88 – Series 400 41
– Series 4000 83 – Series 4000 40
– Series 500 42
C – Generator application 43, 53
Cleaning agent – Limit values 32, 66
– System cleaner 107 – Operational monitoring 32
Cleaning agents 103 – Permissible concentrations 32
Cleaning agents Series 500 109 – Replacement 66
Cleaning instructions Series 500 – Series 4000
– Engine coolant circuit Series 500 108 – Antifreeze for cooling systems containing light met-
– Engine coolant circuit Series 5000 110 als 56, 61
Cleaning specifications – Antifreeze for cooling systems free of light metals
– Assemblies 106 47, 51
– Engine coolant circuit 102, 105 – Storage capability 36
– System cleaner 107 – Test kit 32
Color additive Coolant circuit
– Coolant circuit 37 – Assembly cleaning 106
Combustion air 111 – Cleaning 102, 105
Confirmation – Cleaning agents 103
DCL-ID: 0000047995 - 009

– Operator 119 – Flushing 104

Contact person 123 – Leakage 37
Contaminants – Materials 39
– Fuel 95 Coolant circuit Series 500
– Cleaning 110
– Cleaning agents Series 500 109
– Contamination 108

124 | Appendix B | A001072/06E 2022-03

 Coolants Fresh water
– Engine-generator set – Limit values
– Series 400 64 – Series 400 41
– Series 400 64 – Series 4000 40
– Series 500 67 – Series 500 42
Cooling system Fuel
– Prevention of damage 38 – Condensate 97
– Contaminants 95
D – Silicon content 11
Dust load 113 – Usage 68
Dye additives Fuel gas
– Lube oil circuit 12 – Boundary conditions 93
– Condensate 97
E – Gas analysis with Series 500 94
Engine – Generator application and engine-generator set
– Preservation 5 – Series 400 87, 88
Engine coolant circuit – Series 4000 80, 83
– Assembly cleaning 106 – Series 500 92
– Cleaning 105 – Main elements, subdivision for Series 500 91
– Cleaning agents 103 – Marine application 74
– Contamination 102 – Requirements: Methane Number 69
– Flushing 104 – Silicon compounds 72
Engine coolant circuit Series 500 – Silicon content 11
– Cleaning 110 Fuels 73, 79
– Cleaning agents Series 500 109 – Biogas
– Contamination 108 – Series 400 88
Engine oil – Series 4000 83
– Series 400 20 – Natural gas
– Series 4000 15 – Marine application 74
– Series 500 26 – Series 400 87
– Storage and disposal 28 – Series 4000 80
Engine oil 7 – Series 500 91, 92
Engine oil change intervals – Series 400
– Engine-generator set Series 400 23 – Impurities 89
– Engine-generator set Series 500 27
– Oil analysis G
– Evaluation 27 Gas
– Oil bleed system 23 – Main elements, subdivision for Series 500 91
Engine oil change intervals for Series 4000 and Series Gas analysis
400 – Conversion with Series 500 94
– Limit values 8 Gas mixture
Engine oil limit values – Limit values 111
– Series 4000 and Series 400 Gas operating data 93
– Used gas engine oils 8 Gear oil 19
– Series 500 10
Exhaust aftertreatment system H
– Exhaust condensate 101 Heating water
DCL-ID: 0000047995 - 009

– General 98 – General 114

– NOx reducing agent 99 – Water quality 118
Exhaust condensate 101 Heating water for Series 4000 and 400
– Requirements 115
F Heating water for Series 500
Flushing specifications – Requirements 117
– Assemblies 106 Hotline 123
– Coolant circuits contaminated with bacteria, fungi or Humidity 112
yeast 107
– Engine coolant circuits 102, 104
Flushing specifications Series 500
– Engine coolant circuit Series 500 108

A001072/06E 2022-03 | Index | 125

 I P
Impurities Preservation
– Fuels – Engine 5
– Series 400 89
Information on use 5 R
Requirements
L – Coolant circuit 39
Leakage – Heating water for Series 4000 and 400 115
– Coolant circuit 37 – Heating water for Series 500 117
Leaks Revision overview 120
– Lube oil circuit 12
Lean gas operation 27 S
Limit values Series 500 Service partner 123
– Used gas engine oils 10 Silicon compounds
Liquid Natural Gas (LNG) 71 – Fuel gas 72
List of abbreviations 121 Silicon content
Lube oil – Fuel 11
– Series 4000 15 – Fuel gas 11
Lube oil circuit Silicon operational value 11
– Leaks 12 Spare parts service 123
Lubricating grease Special limit values 95
– Engine-generator set Series 400 25 Storage
– Engine-generator set Series 4000 18 – Coolant 36
– Engine-generator set Series 500 29 Supply air 111
– For generators 18, 25, 29
– General application 13, 14 T
– Requirements 13 Test kit
– Special application 13 – Coolant 102, 108

M U
Materials Used-oil analysis 8
– Coolant circuit 39 Used-oil analysis Series 500 10
Medium in the gas piping leak chamber for marine appli-
cations
– Fuels for gas engines 77

N
Natural gas
– Main constituents 70
– Requirements
– Marine application 74
– Series 400 87
– Series 4000 80
– Series 500 92
NOx reducing agent
– General 99

O
DCL-ID: 0000047995 - 009

Oil bleed system 23

Oil changeover procedure 28
Oil economy 28
Oil sampling 27
Oil volume extension 28
Operational monitoring
– Coolant 32, 66
Operator
– Confirmation 119

126 | Index | A001072/06E 2022-03