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. Then, assess if the power of the selected generator set matches the power demand. 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 components for the diesel generator set.

I. Standard Optional Accessories Included with柴发 Regular Orders

The diesel generator set is primarily composed of Cummins diesel engine, Stanford generator, and PC3.3 control system, the three main components. Taking the C220D5 Cummins generator set as an example, its structure and layout are shown in Figures 1 and 2. The standard configuration mainly 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, and improving the engine's reliability.

② The large-bore design allows for the installation of 4 larger valves, which not only reduces intake resistance and improves inflation efficiency, enhancing fuel economy, but also extends the lifespan of the valves and enhances the reliability of the engine.

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 Increase the optional mounting bracket positions for the fan, enhancing the rigidity of the bracket.

⑤ Utilizes standard low-pressure cylinder sleeves with improved surface roughness.

(2) Cylinder Head

One pot, one lid, easy for maintenance.

② Utilizes a four-valve (two intake and two exhaust) structure, reducing intake resistance and significantly improving fuel injection efficiency, which is conducive to more complete combustion.

③ The exhaust outlet and exhaust channel are improved to a transition change structure, utilizing pulse ducts for optimal utilization of exhaust energy.

④ High-strength cast iron material is selected, further enhancing the cylinder head's impact resistance. Increased valve rigidity results in stronger over-revving capability of the engine.

(3) Crankshaft

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

② The big shaft neck overlap effectively improves the crankshaft's rigidity and strength, enhancing reliability.

③ The original crankshaft structure was a balance weight insertion design, but the new design now features an integrated crankshaft structure, significantly reducing the failure rate of the crankshaft and enhancing its reliability.

④ Corner induction hardening enhances the crankshaft strength, with the crankshaft journal being deep-hardened up to 2.2mm, improving wear resistance.

(4) Pistons and connecting rods

The piston is made of appropriate aluminum alloy material, featuring low inertia during high-speed operation, good thermal conductivity, and sufficient strength to meet working requirements.

② The cylinder skirt design ensures proper fit during operation, featuring adequate bearing surface without being too tight or causing knocking due to excessive gap.

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.

(5) Camshaft

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

② Employing a large-diameter camshaft and large cam structure, the intake profile is improved, slowing the valve seating speed and reducing impact force, thereby enhancing valve wear. Moreover, vibration is minimized, increasing the engine's reliability and durability.

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

(T6) Turbocharger

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

2. Features of the Stanford Generator

Insulation and varnishing:

The insulation grade is "H" class. All wound components are made of specially developed materials and treated with a special process to be varnished, 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 generator windings are wound with a 2/3 pitch, effectively eliminating the third and multiples of the third harmonic of voltage, designed for nonlinear loads such as uninterrupted power supply equipment. 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 oscillation during parallel operation of the generator. This 2/3 pitch winding, with poles and teeth carefully selected, matches to suppress 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) Telephone Interference

THF (as defined in BS EN60034-1) is less than 2%. TIF (as defined in NEMA MG1-22) is less than 50.

(5) Radio Frequency Interference

Brushless units and high-quality AVR ensure minimal interference during radio transmission, meeting the requirements of BSEN61000-6 standards. 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-drive end of the generator. The output box made of steel plate 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 accessories and components. 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, meters, and more.

4. Optional accessories (random selection)

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

Section 2: Optional Attachments for Diesel Generators

The so-called optional accessories are clearly components that are not part of the standard configuration of a diesel generator set. These are added to enhance the generator's functionality and improve performance, and they are purchased separately at an additional cost. The following devices are optional. When ordering from the diesel generator manufacturer, it is necessary to declare the additional purchase requirements in advance to ensure the desired functionality after installation.

Battery Floating Charger

External floating charger with high-charge function, enabling rapid charging of lead-acid batteries and regular charging of battery cells. As shown in Figure 3, the wiring diagram is illustrated in Figure 4. Once the high-charge mode is selected, the output voltage will increase by 0.35V. (Note: High-charge mode must be charged according to the manufacturer's instructions for the battery; otherwise, it 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 restart the output current to recharge the battery to voltage H at its terminal. The shutdown set values 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 to +60° C

(5) Indicator Light: LED Charger Indicator Light

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

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

2. Storage Oil Tank

The fuel tank of the generator set should be capable of providing enough fuel for continuous operation at full load for more than 8 hours, and it is advisable to avoid refueling the tank while the generator set is running. After the fuel tank is placed, the oil level should not exceed 2.5 meters above the base of the diesel generator. If the oil level in the outdoor fuel tank is higher than 2.5 meters, an additional fuel tank should be added between the outdoor fuel tank and the diesel generator set to ensure that the pressure for direct oil delivery 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 intake or fuel injection lines.

3. Dual Power Conversion Cabinet

The main power switch is available in manual and automatic types (abbreviated as ATS). If your diesel generator is used as an auxiliary power source, a main power switch must be installed at the power input point. It is strictly prohibited to supply power to the load by means of temporary wiring and memory-based operations. Because once unauthorized reconnection to the grid (also known as backfeeding) occurs with the self-generated power, it can lead to severe consequences such as 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 designed with an automatic management system to accommodate the 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 generators to be paralleled, outputting a closing signal during synchronization to achieve automatic paralleling. It is equipped with a programmable controller that 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, 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 generator set from cracking due to freezing in winter, and allows for quick and rapid starting of the diesel engine in extremely cold temperatures. The water jacket heater keeps the temperature of the water in the generator set within the set temperature range (about 35 °C), indirectly heating the lubricating oil due to heat transfer, thus avoiding condensation and keeping the diesel generator set in a hot standby state. This enables the generator set to start on emergency at any time, regardless of the severity of winter, and quickly reach full load in a short period, reducing mechanical wear of the diesel generator set and ensuring stable output power. The structure of the water jacket heater is shown in Figure 5.

6. Oil Heater

The oil heater is typically used to heat the fuel tank of a generator set for engine preheating. 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 influence of external temperatures, leading to difficulties in starting the generator set in cold conditions. By using the heater for preheating, we can help ignite the generator set, which also serves as a safeguard. The appearance of the oil heater is shown in Figure 6.

7. Whisper Quiet Generator Sets

The silent type generator set primarily refers to units with protective enclosures, mainly categorized into silent box 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 demand for power facilities in construction power supply, backup power supply, and guaranteed power supply is also increasingly high, especially in terms of noise control, design aesthetics, and equipment hoisting, among other performance characteristics.

Summary:

Selecting brand suppliers with excellent after-sales service and maintenance support ensures user power reliability. As diesel generators are a long-term investment, they may require regular maintenance and repairs. Reliable service support guarantees the long-term dependable 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.