When selecting a diesel generator set, consider its overall performance and economic indicators, the location of the generator manufacturer or distributor, and their actual professionalism, as well as their after-sales service capabilities. Then, assess whether 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 understand 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 to some extent affect the operation and performance of the diesel generator set. This article by Cummins specifically describes the types and main functions of the optional and auxiliary accessories for diesel generator sets.

I. Standard Optional Accessories for柴发常规

The diesel generator set is primarily composed of three major components: Cummins diesel engine, Stanford generator, and PC3.3 control system. Taking the C220D5 Cummins generator set 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 layout and wide skirt design increase the rigidity and strength of the cylinder body, reducing vibration and noise, thereby enhancing the engine's reliability.

② The large cylinder 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 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 development and application of electronic fuel injection technology in the future.

④ Increase the optional installation positions for fan bracket to enhance bracket rigidity.

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

(2) Cylinder Head

One pot, one lid, easy for maintenance.

② Features a four-valve (two intake and two exhaust) configuration, reducing intake resistance and significantly enhancing the filling efficiency, which is conducive to improved 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-strength cast iron material is used, further enhancing the impact resistance of the cylinder head. Increased valve stiffness results in greater over-revving capabilities of the engine.

(3) Crankshaft

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

② Increased overlap of the large shaft neck effectively enhances the crankshaft's rigidity and strength, boosting reliability.

③ The original crankshaft structure was a镶balance weight structure, but now we've adopted an integrated crankshaft structure, significantly reducing the failure rate of the crankshaft and enhancing its reliability.

④ Gear corner induction hardening enhances the crankshaft's strength and improves wear resistance with induction hardening up to 2.2mm depth on the crankshaft journals.

(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 working requirements.

② The barrel design of the piston skirt ensures proper fit during operation, offering sufficient bearing surface while avoiding both excessively tight gaps and the potential for knocking due to overly large gaps.

③ Forged from high-strength alloy steel for the connecting rod, which enhances its strength.

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

Camshaft

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

② Featuring a large-diameter camshaft and large cam structure, the intake profile has been 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 for reliable cam motion path.

(6) Turbocharger

Utilizing small wheel diameters, the compact structure boasts high compression ratios and a wide flow range, effectively reducing exhaust temperatures and enhancing emissions performance of the engine, while also improving reliability. It meets the requirements of 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 ensure the 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 various 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, and are designed for non-linear loads such as uninterrupted power supply equipment. When connected in parallel with the grid, the 2/3 pitch structure suppresses the excessive midline current that can be produced by sometimes larger coil pitches. A fully continuous damping winding reduces oscillation during parallel operation of the generator. This 2/3 pitch winding, with both 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) 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 Frequency Interference

Brushless units and high-quality AVR ensure minimal interference during radio transmission, meeting the requirements of BSEN61000-6 standard. An RFI suppressor can be provided separately if needed.

(6) Terminal Blocks and Junction Boxes

Standard generators are three-phase and can be reconnected to the 12 terminal heads connected to 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 controllers, sensors, meters, and the like.

4. Randomly Required Accessories

(1) Suitable for 40℃/50℃ environment 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, designed to enhance the functionality and performance of the power generation product. These are additional items that require separate purchase. The following devices are optional; they must be specified in advance when ordering from the diesel generator manufacturer to ensure the required functionality after installation.

Battery Float Charger

External floating charger with strong charging function, capable of rapidly charging lead-acid batteries and also performing regular charging. The appearance is as shown in Figure 3, and the wiring diagram is as 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 provided by the battery manufacturer. Failure to do so may damage the battery and increase maintenance costs.) Specifications:

Operation:

The charger outputs current K to the battery terminal voltage reaching the floating charge K setpoint, which is preset. When the battery voltage drops to the lower limit due to load usage, the charger will restart output current to recharge the battery 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 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 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 supplying fuel for continuous operation at full load for more than 8 hours, and it should be avoided to refuel the tank while the generator set is running. After placing the fuel tank, the oil level should not exceed 2.5 meters above the base of the diesel generator. If the oil level in an outdoor fuel storage tank is higher than 2.5 meters, a fuel storage tank should be added between the outdoor storage tank and the diesel generator set to ensure that the direct oil supply pressure does not exceed 2.5 meters. Even during the shutdown period of the diesel generator set, fuel is not allowed to flow into the diesel engine by gravity through the fuel inlet or 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 using temporary wiring methods or relying on memory-based operations. As unauthorized connection to the power grid (referred to as back-feeding) from a self-provided power source can lead to severe consequences such as personal injury 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 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 scheduling of generator operation, ensuring reliable grid operation. In the event 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 generator set from cracking in winter and enabling quick startup of the diesel engine in cold, low-temperature conditions. The water jacket heater keeps the temperature of the generator set's 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 heated standby state. This allows the diesel generator set to be readily started in any season and quickly loaded to full capacity, reducing mechanical wear and ensuring stable output power. The structure of the water jacket heater is shown in Figure 5.

6. Oil Heater

Oil heater is typically used to heat the generator set's fuel tank, providing preheating for the engine. By adding such a device, the generator set can still start normally even in cold conditions or in低温 environments. In低温 conditions, 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 external temperatures, leading to difficulties in starting the generator set in cold weather. Using a heater for preheating can help ignite the generator set and offers a safety measure. The appearance of the oil heater is shown in Figure 6.

7. Silent-type Generator Set

The silent-type generator set primarily refers to units with protective enclosures, mainly divided into silent 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 demand for power facilities in construction power supply, backup power supply, and guaranteed power supply is also increasing, especially with higher requirements for noise control, design aesthetics, and equipment lifting capabilities.

Summary:

Selecting a brand supplier with excellent after-sales service and maintenance support ensures reliable power usage. As diesel generators represent 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 configuration, application areas, and selection considerations can help in choosing the right diesel generator set and ensure a reliable power supply.