Cummins Diesel Generator Set

The Cummins diesel generator sets made in China produced by Kecheng show a reliable performance. This series of units fully adopts original Cummins engines and generators of well-known brands. They have passed 32 strict factory tests including load and insulation, ensuring a start-up success rate of over 99%. The overall performance is superior to industry standards. The product complies with major domestic and international standards such as ISO 8528 and GB/T 2820, with a power coverage range from 7kW to 3750kW, capable of providing stable power for various scenarios including industrial production, emergency backup power, and special operations. Based on ten years of manufacturing experience, Kecheng Electric Power integrates and optimizes the units, providing more adaptable localized solutions while ensuring the original quality.

The set covers the full power range of micro (7-50kW), small (50-200kW), medium (200-1000kW), and large (1000-3750kW):

Application scenarios (Exclusive adaptation for Cummins Power)

1. Emergency backup power scenario (full power range coverage)

Emergency response for super high-rise buildings (1000-3750kW) : For instance, in a project of the same level as the Shanghai World Financial Center, four 2500kVA high-voltage units are connected to the grid for operation. The mains power switch can be completed within 30 seconds, providing uninterrupted power for fire pumps, emergency lighting, and the data center. It supports continuous operation for 10 hours (with a standard 1000L fuel tank).

• Medical system backup (50-200kW) : Specifically designed for hospital operating rooms and icus, Kecheng customizes low-noise units (≤65dB), equipped with an ATS automatic switching system to ensure stable power supply for key equipment such as ventilators and monitors, meeting electromagnetic compatibility standards for medical facilities.

• Commercial complex backup (200-500kW) : Specifically designed for places like Wanda Plaza, it is compatible with elevators, cold chain systems, and security systems. Kecheng optimizes the fuel system, with a fuel consumption as low as 105L/h under 75% load (500kW model), reducing operating costs.

2. Continuous power supply scenarios (200-3750kW)

• Main power supply for mining (500-1000kW) : Equipped with KTA38-G5 engine, it can withstand harsh environments such as dust and vibration. The body frame and dust-proof filter core are reinforced by Kecheng (intake resistance ≤6.23kPa), supporting 24-hour continuous operation, and is suitable for heavy equipment such as crushers and roadheaders.

• Power supply for islands and remote areas (100-500kW) : Customized high-altitude models (supporting an altitude of 3000 meters) with windproof and sand-proof design, equipped with large-capacity fuel tanks and remote operation and maintenance modules, solving the problem of difficult replenishment. It has been applied to the CNOOC offshore platform project.

• Main power supply for industrial parks (1000-3750kW) : Multiple units operate in parallel, with a total capacity of up to 10MVA. Kecheng provides an intelligent control solution that is linked with the factory's DCS system to achieve automatic load distribution and reduce energy waste.

3. Special operation scenarios (7-500kW)

• Engineering emergency mobile power supply (50-200kW) : Trailer-mounted design, equipped with hydraulic support and braking system, suitable for road maintenance and post-disaster rescue. Cummins engine has excellent cold start performance (start success rate ≥95% at -20℃), and can be put into use within 3 minutes.

• Temporary power supply for event venues (100-500kW) : As in the configuration plan of the Shenzhen Universiade venue, silent units (≤70dB) are adopted, supporting multiple units in parallel to meet the requirements of event equipment and broadcasting systems, with power supply stability reaching 99.99%.

• Agricultural irrigation power supply (7-50kW) : Small units are suitable for rural water conservancy stations. Kecheng simplifies the operation interface and maintenance process. Made of corrosion-resistant materials, it can adapt to the humid environment in the field. The fuel consumption is 8%-10% lower than that of similar products.

Product Advantages (Kecheng Customization + Cummins Power)

Technical parameters (Full power range of 7-3750kW)

Technical features (Cummins Core + Kecheng Innovation)

1. Technical advantages of the power system

• Cummins original engine: It adopts an integrated cylinder block design (with 40% fewer parts than similar ones), is equipped with a PT fuel pump direct injection system and turbocharging intercooling technology, and the combustion efficiency is increased by 20%. The maximum power of the KTA50-G3 model can reach 1227kW.

• Low-loss generator: Equipped with Stanford/Lillessen brushless generators, insulation class H (temperature resistance 155℃), excitation response time ≤0.3 seconds, voltage stability accuracy ±1%, suitable for sensitive loads such as medical equipment and precision instruments;

• High-efficiency fuel system: Kecheng optimizes the fuel pipeline and filter configuration, supporting 0#/-10#/-35# light diesel. The fuel filter replacement cycle is extended to 3,000 kilometers, reducing maintenance frequency.

2. Intelligent control and operation and maintenance system

• Multi-level control system: Small units are standard equipped with DeepSea DSE7320 (automatic start-stop and overload protection), while medium and large units are upgraded to the PowerCommand cloud platform to achieve remote monitoring (rotational speed, oil pressure, water temperature), fault early warning (more than 10 types of fault codes), and operation and maintenance reminder functions;

• Parallel operation technology innovation: Kecheng independently developed a parallel operation controller, supporting 4 to 8 units to be connected in parallel simultaneously, with a load distribution accuracy of ≤±2%. It has been applied to the 2400kW project of Dongguan Minglitong Financial Data Center.

• Fault diagnosis system: It monitors key parameters such as engine cylinder pressure and generator insulation in real time. When abnormalities occur, it automatically reduces load or stops the machine, and simultaneously pushes maintenance plans to the mobile phones of management personnel, increasing the efficiency of fault resolution by 60%.

3. Environmental adaptation and structural optimization

• Extreme environment adaptation: The low-temperature model is equipped with an intake electric preheating device and a 6.6kW starter (starts successfully at -40℃), the high-altitude model has a custom turbocharger (power attenuation ≤5% at an altitude of 3000 meters), and the high-temperature model has an upgraded radiator (can withstand an environment of 50℃).

• Noise reduction and vibration damping design: The body structure is optimized through CAE simulation, and it is equipped with a double-layer sound insulation cover (inner layer of sound-absorbing cotton + outer layer of damping board) and rubber vibration damping pads. The noise of the silent unit is 10-15dB lower than the industry standard.

• Lightweight and compact design: The micro units feature an aluminum alloy frame, reducing weight by 15%. The small units can be integrated with trailers (with braking systems) for rapid transfer and deployment.

Power Selection (Precise Matching Guide)

1.Core Selecting basis

2.Power recommendation for typical scenarios

Usage Method (Operating Specifications by Power segment)

1.Pre-startup inspection (Core Steps)

2.Startup operation process

(1)Micro/small units (7-200kW)

1. Close the battery switch and switch the controller to the "Automatic" mode;

2. In a low-temperature environment (≤5℃), press the preheating button (30 seconds), then press the start button, and observe the engine speed (1500RPM±50RPM) and oil pressure (≥0.3MPa).

3. Run without load for 3 minutes and then gradually load. First, load 50% of the load and run for 5 minutes, then increase to full load.

(2) Medium/large units (200-3750kW)

1. Check the closing condition of the high-voltage distribution cabinet door, confirm reliable grounding, and start the cooling system;

2. Start the unit through the PowerCommand controller and monitor the cylinder pressure (≥ 90% of the standard value), water temperature (≤93℃) and excitation voltage.

3. Load in stages of "25%→50%→75%→100%", with a 10-minute interval between each stage. Grid-connected units need to adjust the load distribution simultaneously.

3. Operation monitoring and shutdown

• Key points of real-time monitoring

① Engine: Oil pressure (low idle speed ≥0.138MPa, rated speed 0.345-0.483MPa), water temperature (82-93℃), exhaust temperature (≤529℃);

② Generator: Voltage deviation (±1%), frequency fluctuation (±0.5Hz), load current (not exceeding rated value);

③ Fuel system: Fuel pressure (stable without fluctuation), fuel consumption (deviation from standard value ≤10%).

• Exception handling:

① Sudden drop in oil pressure: Stop the machine immediately, check the oil level and oil filter, and replace the oil if necessary.

② Voltage fluctuation: Reduce the load to 50%, inspect the excitation system, and contact Kecheng after-sales service for calibration.

③ High-temperature alarm: Turn on the backup cooling fan, check the coolant level and radiator. If there is no effect, stop the machine.

• Shutdown process:

① Gradually unload to no-load and run no-load for 5 to 10 minutes (15 minutes for large units);

② Press the stop button to turn off the cooling system and the battery switch.

③ If the machine is to be shut down for a long time (≥7 days), the accumulated water in the fuel tank should be drained, the battery switch disconnected, and a dust cover covered.

Safety and Protection Regulations

1. Installation safety requirements

• Site requirements: The distance between the unit and the wall should be no less than 1.5 meters, with good ventilation. Large units should be equipped with shock-absorbing foundations, and high-pressure units should be surrounded by safety fences (with a height of no less than 1.8 meters).

• Electrical safety: Grounding resistance ≤4Ω (low voltage) /≤10Ω (high voltage), cable cross-section meets the current-carrying capacity requirements, high-voltage wiring is operated by certified personnel.

• Fire protection configuration: Two 8kg ABC dry powder fire extinguishers are provided. The distance between the fuel tank and the unit should be no less than 5 meters. The use of plastic fuel containers is strictly prohibited.

2. Safety precautions for operation

• It is strictly prohibited to open the body panel or the high-voltage cabinet door when the unit is in operation. Non-operating personnel are also prohibited from operating the controller.

• Overloading operation is prohibited (continuous load does not exceed the commonly used power), and the use of inferior fuel (sulfur content ≤0.5%) is also prohibited.

• Maintenance is strictly prohibited without cutting off the power supply and fuel supply. It is also forbidden to use water to extinguish fuel fires (dry powder fire extinguishers should be used).

3. Maintain safety regulations

• Before maintenance, hang the "Do Not Start" sign, disconnect the battery switch from the main power supply, and release the fuel pressure.

• When replacing the filter element, use special tools to avoid fuel leakage. Insulating gloves should be worn when maintaining high-voltage components.

• After maintenance, conduct no-load tests (10 minutes) and load tests (30 minutes). Only after confirming that there are no abnormalities can it be put into use.

Maintenance and Servicing Periodic Table (Kecheng Customized Version)