500kW generator set

The 500kW generator set by Kecheng is made in China. The core of the unit adopts Chongqing Cummins engine and Lille Semir brushless generator, combined with the self-starting control system, achieving high reliability and rapid response. The power supply is automatically started within 15 seconds after the main power supply is cut off, and the standby power is up to 500kW.This product adopts integrated containerization design, compact structure, easy to move and install, and meets the relevant national and international standards.It has low fuel consumption during operation and stable performance, making it particularly suitable for places with extremely high requirements for power supply continuity, such as hospitals, data centers, industrial parks, and major event support.

Appearance drawing of Kecheng 500kW generator set

Core advantage

Analysis of Cummins Engine Performance

As the power core of the unit, Chongqing Cummins KTA19-G8 engine adopts 6-cylinder in-line layout, cylinder diameter × stroke 159mm×159mm, displacement 18.9L, and achieves 575kW reserve power output through turbocharging intercooling technology. Its PT direct fuel injection system, in combination with an electronic governor, reduces fuel consumption to as low as 206g/kw·h (75% load), which is 8% lower than that of similar models. The design of high-strength alloy cast iron cylinder block and integral forged steel crankshaft ensures that the major overhaul interval exceeds 20,000 hours and is suitable for a wide temperature range from -20℃ to 40℃.

Technical highlights of Leroy Somer generators

Lillesemma brushless generator (protection class IP23, insulation class H) adopts AVR automatic voltage regulation system, steady state voltage adjustment rate ≤±1%, transient voltage recovery time < 3 seconds, to ensure safe operation of sensitive loads such as medical equipment and precision instruments. The generator is equipped with a PMG permanent magnet excitation system, which maintains stable output even when the power grid fluctuates. The telephone harmonic coefficient THF is less than 2%, meeting the strict requirements for power quality of communication base stations, etc.

Intelligent self-starting system

The 500kW diesel generator set is equipped with an LCD Chinese liquid crystal numerical control system, supports ATS dual power supply switching, and features mains undervoltage detection (response time < 0.5 seconds), three-time start-up retry logic and self-diagnosis of faults. The 24V DC starting system, in combination with the water jacket heater, achieves a starting success rate of 99% in an environment of -15℃.The remote monitoring module can upload 16 operating parameters such as voltage, frequency and oil pressure in real time, and support data access between mobile APP and PC.

Technical Parameter

Generator features

Structural design highlights

• Modular layout: The engine, generator and control system are flexibly connected through shock-absorbing pads to reduce vibration transmission (amplitude ≤0.3mm) and extend the service life of the equipment.

- Low noise optimization: By using a double-layer sound insulation cover (inner layer of sound-absorbing cotton + outer layer of steel plate), combined with an impedance composite muffler, the noise can be reduced to 75dB (a soundproof box module is required as an option).

-Maintenance convenience: The engine's Oil Filter, Fuel Filter and other vulnerable parts are centrally arranged. Daily maintenance does not require disassembling peripheral components, saving 50% of maintenance time.

Environmental adaptability

The unit has passed the GB/T 2423.16 mold test (grade ≤2) and seismic strength test (horizontal acceleration 0.2g), and can operate for a long time in an environment with an altitude of ≤1000m and a relative humidity of ≤90% (no condensation). The fuel system is compatible with 0# diesel (summer) and -10# diesel (winter), and is equipped with an oil-water separator (with a filtration accuracy of 10μm) to ensure reliability in areas with high sulfur fuel content.

Usage method

Checking process before starting up

• Fuel system: Check that the fuel level in the fuel tank is ≥30%, open the fuel valve, and expel all the air in the pipeline (press the fuel pump by hand until the resistance increases). - Electrical system: Battery voltage ≥24V, the control panel displays the "standby" state, and the emergency stop button is reset. - Mechanical inspection: The oil level should be between the H/L mark on the dipstick, the coolant level should reach two-thirds of the expansion tank, and the tension of the fan belt should be such that the press deflection is 10-15mm.

Startup operation steps

• Automatic Mode: Turn the control panel knob to "Automatic", and the system will enter the mains power monitoring state. It will automatically start when the mains power is interrupted (the ATS switching time after successful startup is less than 10 seconds).

- Manual mode: Press and hold the "Start" button for 3 seconds. Once the speed rises to 1500rpm and the voltage stabilizes, close the output circuit breaker (pay attention to the frequency meter showing 50±0.5Hz).

- Loading requirements: After starting, idle for 3 minutes (oil pressure ≥0.3MPa), gradually increase the load to 50%, and after running for 10 minutes, it can be increased to full load.

Shutdown Operation Specification

• Normal shutdown: First, remove the load, let the engine idle for 5 minutes (to prevent the turbocharger from overheating), press the "Stop" button, and then close the fuel valve after the speed drops to 0.

- Emergency stop: When the oil pressure is less than 0.2MPa, the water temperature is greater than 105℃, or abnormal noises occur, immediately press the red emergency stop button. After the incident, the fault must be checked before restarting.

- Long-term shutdown: Start up once a week (run for 30 minutes), replace the battery electrolyte monthly (if the ambient humidity is greater than 75%), and add preservatives to the fuel tank.

Precautions

Environmental requirements

• Installation site: The distance between the unit and the wall should be no less than 1.5m, and the area of the air inlet should be no less than 2.5㎡ to ensure the circulation of cold air (3m³/min air volume is required for each kW of power).

- Emission requirements: The exhaust pipe must be equipped with a rain cap. The slope of the horizontal section should be no less than 3°. The outlet should be kept away from the air inlet (a distance of more than 5 meters) to prevent the backflow of exhaust gas.

- Fire Protection Regulations: The computer room is equipped with 2 8kg dry powder fire extinguishers. The distance between the oil tank and the unit should be more than 1m. The ground should be treated to prevent oil seepage (it is recommended to use epoxy resin coating).

Maintenance cycle

Safety Warning

It is strictly prohibited to open the guardrail during operation. The surface temperature of the generator end cover can reach 120℃, which is prone to cause burns. Before maintenance, the main circuit breaker must be disconnected and a "Do Not Close" sign hung. The capacitor discharge time should be no less than 5 minutes. During the thunderstorm season, the grounding resistance should be tested to be ≤4Ω, and the operating voltage of the lightning arrester should be set at 420V (line voltage).

Application Case

The 500kW generator set of Kecheng has been serving key projects such as the automated terminal of Qingdao Port (to be put into use in 2023) and the emergency power supply system of Qilu Hospital (to be installed in 2024). During the summer power rationing period in Weifang in 2024, a certain chemical enterprise adopted this unit to ensure the continuous operation of key production lines. It provided power for a total of 1,260 hours, with an average mean time between failures of 480 hours. The fuel consumption was reduced by 1.2 tons compared with that of the same power brand.