When selecting a diesel generator set, consider its overall performance and economic indicators, the location and actual expertise of the generator manufacturer or dealer, and whether they offer after-sales service capabilities. Then, consider whether the power of the selected generator set matches the power load. The Cummins diesel generator set standard configuration includes not only the Cummins diesel engine and the Stamford generator as the main units but also the auxiliary components provided. You can learn about the basic information of the standard configuration by referring to the technical specifications in the Cummins power product manual, the quotation sheet, and the information published on the Cummins website. If the standard configuration is missing, it may affect the use and performance of the diesel generator set to some extent. This article by Cummins specifically describes the types and main functions of the optional and accessory items for the diesel generator set.

1. Standard Optional Accessories for Diesel Generator Supply

The diesel generator set is primarily composed of Cummins diesel engines, Stanford generators, and PC3.3 control systems, the three main components. Taking the Cummins generator set model C220D5 as an example, its structure and layout are shown in Figures 1 and 2. The standard configuration includes the following:

1. Features of Cummins diesel engines

(1) Cylinder Body

Enhanced rib arrangement and wide skirt design enhance the rigidity and strength of the cylinder body, reducing vibration and noise, thereby improving the engine's reliability.

② Large cylinder bore design, accommodating 4 larger valves, not only reduces intake resistance and improves filling efficiency, enhancing fuel economy, but also extends valve life and boosts engine reliability.

③ Added special oil and water extraction holes, as well as mounting holes for STC and electronic fuel injection systems, which are conducive to the future development and application of electronic fuel injection technology.

④ Add optional fan bracket mounting positions for improved rigidity.

⑤ Utilizes a universal low-pressure cylinder sleeve, improving surface roughness.

(2) Cylinder Head

One pot, one lid, easy for maintenance.

② Featuring a four-valve (two intake, two exhaust) design, it offers minimal intake resistance, significantly enhancing fuel injection efficiency and promoting complete combustion.

③ The exhaust outlet and exhaust channel are improved to a transition change structure, utilizing pulsating air channels for more efficient energy utilization of exhaust gases.

④ High-strength cast iron material is used, further enhancing the impact resistance of the cylinder head. Increased valve stiffness results in improved over-revving capability of the engine.

(3) Crankshaft

Forged from high-strength alloy steel material, enhancing crankshaft strength and lifespan.

② The overlap of the main shaft neck effectively enhances the rigidity and strength of the crankshaft, improving reliability.

③ The original crankshaft structure was the镶balance weight design, but now it has been upgraded to an integrated crankshaft structure, significantly reducing the failure rate of the crankshaft and enhancing its reliability.

④ Induction hardening at the corner of the garden, enhancing the crankshaft's strength; induction hardening to a depth of 2.2mm at the crankshaft journals, improving wear resistance.

(4) Pistons and connecting rods

The piston is made of suitable aluminum alloy material, featuring low inertia at high speeds, excellent heat conduction, and sufficient strength to meet operational requirements.

② The cylinder skirt design with a drum surface ensures proper fit during operation, providing sufficient bearing surface without being too tight or causing knocking due to excessive gaps.

③ The connecting rod is forged from high-strength alloy steel material, enhancing its strength.

④ Type I linkage structure, ensuring the required strength with less material.

Camshaft

Manufactured from high-strength alloy steel, enhancing camshaft strength and lifespan.

② Employing a large-diameter camshaft and large cam structure, the intake contour is improved, slowing the valve seating speed and reducing impact force, thereby enhancing valve wear. Additionally, vibration is reduced, leading to increased engine reliability and durability.

③ Cam surface is ultra-fine polished, ensuring reliable cam motion path.

(6) Turbocharger

Utilizing small wheel diameters, the compact structural dimensions, high compression ratio, and wide flow range effectively reduce the engine's exhaust temperature, improve emissions performance, and enhance reliability. This meets the requirements of high-power engines and the matching needs of high-altitude engines.

2. Features of the Stanford Generator

Insulation and varnishing:

The insulation grade is "H." All wound components are made from specially formulated materials and coated with a special varnish process, ensuring reliable operation of the generator in harsh environments. The specially developed resin-based material provides high processing strength and high mechanical strength for the coils and rotating parts.

(2) Winding and electrical performance:

All Stanford generators are wound with a 2/3 pitch, effectively eliminating the third harmonic and its multiples of the voltage, designed for uninterrupted power supply equipment and nonlinear loads. When paralleled with the grid, the 2/3 pitch structure suppresses the excessive midline current that can be produced by larger coil pitches. A fully continuous damping winding reduces oscillation during parallel generator operation. This 2/3 pitch winding, with both poles and teeth carefully selected, suppresses waveform distortion of the output voltage.

(3) Overload Capacity:

The Stanford land-based generator can operate at 110% overload for 1 hour every 12 hours.

(4) Phone Interference

THF (as defined by BS EN60034—1) is less than 2%. TIF (as defined by NEMA Mgl-22) is less than 50.

Radio Frequency Interference

Brushless units and high-quality AVR ensure minimal interference during radio transmission, meeting the requirements of BSEN61000-6 standard. An additional Radio Frequency Interference (RFI) suppressor is available upon request.

(6) Terminal blocks and junction boxes:

Standard generators are three-phase and can be reconnected to the 12 connection terminals at the terminal board, which is mounted on the non-driven end of the generator. The junction box made of galvanized steel contains an AVR and has ample space for user wiring. For ease of operation, the panel is removable.

3. Control System

Control systems refer to the controller section and its matching electrical components and electrical elements. Controllers are mainly categorized into single-machine controllers, multi-machine parallel controllers, and unmanned three remote controllers. Electrical components generally include circuit breakers, relays, speed control panels, sensors, instruments, and more.

4. Randomly Required Accessories

(1) Suitable for 40℃/50℃ environment radiator reservoir, belt-driven cooling fan, fan safety guard.

Section II: Optional Attachments for柴发

The so-called optional accessories are clearly components that enhance the expandability and performance of the power generation products, beyond the standard configuration of the diesel generator set, and these are all additional purchases that require extra payment. The following devices are optional; when ordering from the diesel generator manufacturer, it is necessary to declare the additional purchase requirements in advance to achieve the required functionality after installation.

Battery Float Charger

External floating charger with strong charging function, enabling rapid charging of the battery and regular charging of the battery cells. Its appearance is shown in Figure 3, and the wiring diagram is shown in Figure 4. Once the strong charging mode is selected, the output voltage will rise by 0.35V. (Note: Strong charging mode must be charged according to the instructions for battery production. Failure to do so may damage the battery and increase maintenance costs.) Specifications:

Operation:

The charger outputs current K to the battery terminal until the voltage reaches the float charge K setpoint, which is already established. When the battery voltage drops to the lower limit due to load usage, the charger will re-supply output current to charge the battery M to its terminal voltage H. The shutdown setpoints are listed in Table 1 below.

(2) AC Input: 220-250VAC, 50/60Hz (specify at time of order)

(3) Output Current: 3A or 5A (specify at time of order)

(4) Environmental Temperature Range: -10°C to +60°C

(5) Indicator Light: LED Charger Indicator Light

(6) Protection Features: Short circuit, overvoltage 11, overcurrent, polarity reversal, reverse charging mode: 0.35V higher than float charging voltage.

(7) DC Output: Rated 12VDC or 24VDC (specify at time of order)

2. Oil Storage Tank

The fuel tank of the generator set should be capable of storing enough fuel to sustain continuous operation at full load for over 8 hours, and it is advisable to avoid refueling the tank while the generator set is running. After placing the fuel tank, the oil level must not exceed 2.5 meters above the base of the diesel generator. If the oil level in an outdoor fuel tank is higher than 2.5 meters, a fuel storage tank should be added between the outdoor fuel tank and the diesel generator set to ensure the direct oil pressure does not exceed 2.5 meters. Even during the shutdown of the diesel generator, fuel is not permitted to flow into the diesel engine by gravity through the intake or fuel injection lines.

3. Dual Power Conversion Cabinet

The main power switch comes in two types: manual and automatic (abbreviated as ATS). If your diesel generator is used as an auxiliary power source, it is mandatory to install a main power switch at the input point of the power supply. It is strictly prohibited to input self-provided power to the load by relying on temporary wiring methods or memory-based operations. Because once unauthorized reverse power feeding (abbreviated as backfeeding) occurs, it can result in serious consequences such as personal injuries and equipment damage. The installation of the switch must be inspected and approved by the local power supply department before it can be put into use.

4. Parallel cabinet

The paralleling cabinet for diesel generators is equipped with an automatic management system to accommodate simultaneous use of two or more generators, featuring all the functions of a manual paralleling panel. When the switch is set to the "Automatic" position, the automatic synchronizer can automatically adjust the frequency and phase of the units to be paralleled, outputting a closing signal during synchronization for automatic paralleling. It includes a programmable controller that can automatically control load balancing, load demand, and unit operation scheduling, ensuring reliable grid operation. In case of a power failure, it can automatically start the generator set, perform automatic paralleling, and monitor various faults in the paralleled system.

5. Water Heater

The diesel generator set water jacket heater maintains a certain temperature for the engine, preventing the diesel generator set from cracking in winter and allowing for quick and easy starting in extreme cold temperatures. The water jacket heater keeps the temperature of the water in the generator set's jacket within the set temperature range (approximately 35 °C). As the lubricant is indirectly heated through heat transfer, condensation is avoided, keeping the diesel generator set in a warm standby state. This ensures that the generator set can be started on emergency at any time, regardless of the severe winter, and can be loaded to full capacity within a short period. The mechanical wear of the diesel generator set is reduced, and the output power remains stable. The structure of the water jacket heater is shown in Figure 5.

6. Oil Heater

Oil heaters are typically used as heating elements in the fuel tanks of generator sets to preheat the engine. By adding such a device, the generator set can still start normally even in cold conditions or in environments with low temperatures. In cold environments, such as winter in northern China, the engine in the generator set may not reach the ignition point of the oil in the tank due to the external temperature, leading to difficulties in starting the generator set in cold weather. Using a heater for preheating can help ignite the generator set and serves as a safeguard. The appearance of the oil heater is shown in Figure 6.

7. Silent-type Generator Set

Noiseless generator sets mainly refer to those equipped with protective enclosures, which are primarily divided into noiseless cabinet-type generator sets (as shown in Figure 7) and container-type generator sets (as shown in Figure 8). Key features include low noise and high mobility. With the continuous development of urbanization, the requirements for power facilities in construction power supply, backup power supply, and guarantee power supply are continually increasing, especially for higher demands in noise control, design aesthetics, and equipment lifting capabilities.

Summary:

Selecting a brand supplier with excellent after-sales service and maintenance support is a guarantee for users' electricity use. As diesel generators are a long-term investment, they may require regular maintenance and repairs. Reliable service support ensures the long-term reliable operation of the equipment. Since diesel generator sets play a crucial role in various fields, understanding their configuration, application areas, and selection considerations can help in choosing the right diesel generator set and ensure a reliable power supply.