When selecting a diesel generator set, consider its comprehensive performance and economic indicators, the location and actual expertise of the generator manufacturer or dealer, and their after-sales service capabilities; then assess whether the power output of the chosen generator set matches the electrical load power. The standard configuration of Cummins diesel generator sets includes not only the Cummins diesel engine and 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, quotes, and 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 auxiliary accessories for diesel generator sets.

Section 1: Standard Optional Accessories Included with Chai Fa Regular Products

The diesel generator set is primarily composed of the Cummins diesel engine, the Stanford generator, and the PC3.3 control system as 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 cylinder body's rigidity and strength, reducing vibration and noise, thereby boosting 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 mounting bracket positions for improved rigidity.

⑤ Utilizes universal low-pressure cylinder bushes, with improved surface roughness.

(2) Cylinder Head

One pot, one lid, easy for maintenance.

② Utilizes a four-valve (two intake, two exhaust) configuration, featuring low intake resistance, significantly enhancing filling efficiency and promoting more complete combustion.

③ The exhaust outlet and exhaust duct have been improved to a transition change structure, utilizing pulsating air ducts for optimal utilization of exhaust energy.

④ High-intensity cast iron material is used, further enhancing the cylinder head's impact resistance. Increased valve rigidity allows for greater 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 an insert-type balance weight design, but the new design now employs 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, and the induction hardening of the crankshaft journals up to 2.2mm in depth, improves the wear resistance of the crankshaft.

(4) Pistons and connecting rods

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

② The barrel design of the piston skirt ensures proper fit during operation, with adequate bearing surface and a gap that is neither too small nor too large to cause knocking.

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

High-strength alloy steel material manufacturing enhances camshaft strength and lifespan.

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

③ Cam surface is ultra-fine polished to ensure reliable cam movement path.

(6) Turbocharger

Utilizing small wheel diameters, the compact structure offers high compression ratios and a wide flow range, effectively reducing exhaust temperatures and improving emissions performance, enhancing reliability. It meets the requirements of high-power engines and adapts to high-altitude engine matching needs.

2. Features of Stanford Generator

Insulation and varnishing:

The insulation grade is "H" class. All wound components are made from specially formulated materials and treated with a special varnishing process to ensure reliable operation of the generator in harsh environments. The specially developed resin-based materials provide 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 and multiples of the third harmonic of voltage, designed for uninterrupted power supply equipment and nonlinear loads. When connected in parallel with the grid, the 2/3 pitch structure suppresses excessive midline current that can be produced by larger coil pitches. A fully continuous damping winding reduces oscillations during parallel operation of the generator. This 2/3 pitch winding, with 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 MG1-22) is less than 50.

Radio 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 Suppressor (RFI) can be provided if needed.

(6) Terminal blocks and junction boxes:

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

3. Control System

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

4. Randomly Required Accessories

(1) 40℃/50℃ environment-suited radiator tank, belt-driven cooling fan, fan safety guard.

Section 2: Optional Attachments for Diesel Generators

Optional accessories refer to components that are not part of the standard diesel generator set configuration. These are used to enhance the power generation product with additional features and improve overall performance, all of which are purchased separately. The following are optional items; when ordering from the diesel generator manufacturer, it is essential to declare the additional purchase requirements in advance to ensure the desired functionality after installation.

Battery Float Charger

External floating charger with strong charging function, enabling rapid charging of lead-acid batteries and regular charging of battery cells. As shown in Figure 3, the wiring diagram is 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 battery manufacturer's instructions. Failure to do so may damage the battery and increase maintenance costs.) Standard:

Operation:

The charger outputs current K to the battery terminal until the terminal voltage reaches the float charge K set value, which is pre-set. 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 up to its terminal voltage H. The shutdown set values are listed in Table 1 below.

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

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

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

(5) Indicator Light: LED Charger Indicator Light

(6) Protection Functions: Short Circuit, Overvoltage 11, Overcurrent, Reverse Polarity, Reverse Charging Mode: Higher Float Voltage by 0.35V.

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

2. Fuel Storage Tank

The fuel tank of the generator set should be capable of providing enough fuel for 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 the outdoor fuel storage tank is higher than 2.5 meters, a fuel storage tank should be added between the outdoor fuel storage tank and the diesel generator set to ensure that the direct oil pressure does not exceed 2.5 meters. Even during the shutdown of the diesel generator, fuel is not allowed to flow into the diesel engine by gravity through the fuel intake or injection lines.

3. Dual Power Supply Converter Cabinet

The mains power switching switch is available in manual and automatic (abbreviated as ATS) types. If your diesel generator is used as an auxiliary power source, a mains power switching switch must be installed at the power input point. It is strictly prohibited to input self-generated power to the load by relying on temporary wiring methods and memory operations. Because once unauthorized power feed (abbreviated as backfeeding) occurs, it can cause serious consequences such as injuries to personnel and damage to equipment. The correct installation of the switching 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 the simultaneous operation of two or more generators. It includes 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 generators to be paralleled, outputting a closing signal during synchronization to achieve automatic paralleling. An internal programmable controller is included, which can automatically control load balancing, load demand, and generator scheduling to ensure reliable grid operation. In the event of a power failure, the generator set can automatically start, paralleling automatically, and monitor various faults in the paralleling system.

5. Water Heater

The diesel generator set water jacket heater maintains a certain temperature for the engine, preventing the generator set from cracking in winter, and enabling the diesel engine to start quickly in extreme cold conditions. The water jacket heater keeps the water temperature in the generator set water jacket within the set temperature range (approximately 35 °C). As the lubricating oil is indirectly heated through heat transfer, condensation is avoided, keeping the generator set in a hot standby state. This allows the diesel generator set to be started on emergency at any time, regardless of the severe winter, and to reach full load in a short time. 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 commonly 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 low-temperature environments. In cold environments, such as winter in northern China, the engine in the generator set may fail to reach the ignition point of the oil in the tank due to the influence of external temperatures, leading to difficulties in starting the generator set in cold conditions. Using an oil 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

Silent-type power generating sets primarily refer to units equipped with protective enclosures, mainly categorized into silent cabinet-type generating sets (as shown in Figure 7) and container-type generating sets (as shown in Figure 8). Key features include low noise and high mobility. With the continuous development of urbanization, the demand for power facilities in construction power supply, backup power supply, and guaranteed power supply is also constantly increasing, especially in terms of noise control, design aesthetics, and equipment hoisting, where performance characteristics are more critical.

Summary:

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