Diesel Generator Set

As a China factory integrating R&D, manufacturing and sales, Kecheng is able to to offer mature and reliable diesel generator set product solutions.The unit is based on high quality diesel engine, with high efficiency generator and intelligent control system. It can start up quickly and achieve functions such as emergency response in case of mains power interruption and independent power supply in areas without electricity. The fuel consumption of the unit during operation is relatively low, its service life is long, and daily maintenance is also relatively simple. Its core components provide up to 2 years or 8000 hours of warranty to ensure quality.And all the series 's scope of application is between 10-2000kW.The equipment has been widely used in industrial production, municipal construction, commercial places, outdoor work and other scenarios, is worth considering the power supply solution.

Application Scenarios

1. Industrial production field

• Applicable scenarios: Manufacturing production lines (automobiles, electronics, mechanical processing), key equipment in chemical enterprises (reactors, transfer pumps), mining equipment (crushers, ventilators)

• Core values: Respond to power grid fluctuations or unplanned power outages to prevent order breaches and equipment damage caused by production disruptions. Supports heavy-load start-up (capable of withstanding 3 times the rated current), compatible with high-load equipment such as motors and compressors, ensuring continuous production.

2. Municipal and public service sectors

• Applicable scenarios: Hospital emergency rooms, operating rooms, intensive care units (icus), urban sewage treatment plants, water supply booster stations, emergency lighting and dispatching systems in subways, airports and railway stations

• Core value: Startup within ≤15 seconds after power failure, meeting the power supply requirements for "first-class load" as stipulated in GB 50052-2009 "Code for Design of Power Supply and Distribution Systems", ensuring uninterrupted public services and preventing public accidents.

3. Commercial and civilian fields

• Applicable scenarios: Large shopping malls, chain supermarkets (cold chain refrigeration, elevator operation), high-end hotels, office buildings (central air conditioning, emergency lighting), remote villages, villa areas (independent power supply)

• Core value: Low noise operation (model with noise reduction cover ≤75dB@10 meters), avoiding disturbance to residents; It can be matched with the ATS automatic transfer switch to achieve seamless switching between "mains power" and "unit", ensuring the continuity of life and business operations.

4. Outdoor and temporary work areas

• Applicable scenarios: Construction sites (tower cranes, electric welding machines, temporary office areas), oil exploration, field surveying and mapping (equipment power supply, domestic electricity), temporary power supply for large-scale events (exhibitions, sports events, concerts)

• Core value: Equipped with a mobile trailer design (optional), it is convenient for relocation. It can adapt to harsh environments (temperature range of -30℃ to 45℃, IP24 protection rating), is dust-proof and water-proof, and meets the requirements of outdoor operations.

5. Peak shaving and reserve fields of power grids

• Applicable scenarios: Industrial parks, large factories (replacing municipal power supply during peak grid hours to reduce electricity costs), backup power sources for new energy power stations (photovoltaic and wind power) (making up for intermittent power generation gaps)

• Core value: High power generation efficiency (thermal efficiency ≥40%), flexible adjustment of output power according to load demand, and reduction of energy waste; Support grid-connected operation (in compliance with GB/T 19939-2005 standard), and participate in peak shaving and revenue increase of the power grid.

Product Advantages (Core Competitiveness of Kecheng)

Technical parameters (Mainstream models of Kecheng)

Technical features (Patented technology of Kecheng)

1. High-efficiency power system

• Engine adaptation: Our diesel generator sets adopt Yuchai YC6B, Weichai WP10, Cummins QSB series engines, using high pressure common rail fuel injection technology (injection pressure ≥1600bar), more full combustion, thermal efficiency increased to 40%-45%;With the turbocharging system, the air intake is increased by 20%, and the power output is stronger.

• Generator technology: It adopts a brushless self-excited synchronous generator, with a voltage establishment time of ≤0.5 seconds, a voltage regulation rate of ≤±1%, and a waveform distortion rate of ≤5%. It can stably supply power to precision equipment (such as computers and medical instruments), avoiding damage to the equipment due to voltage fluctuations.

2. Intelligent control system

• Self-developed controller:KCPLC-03 controller supports "automatic/manual/remote" three-mode operation, real-time monitoring of speed, oil pressure, water temperature, voltage, current and other 20 + parameters, "high water temperature", "low oil pressure", "overvoltage" and other faults, automatic shutdown and record the fault code (storage 100), convenient for quick investigation.

• Remote operation and maintenance function: support 4G/WiFi networking, remote start and stop, parameter check, fault alarm push through the "Kecheng Power" APP, suitable for unattended scenes (such as remote base stations, sewage treatment plants); It can be connected to the user's intelligent management platform to achieve centralized monitoring of multiple units.

3. Strengthen protection and noise reduction design

• Environmental adaptability: the outer cover of the unit is made of double cold rolled steel plate (the inner layer is pasted with 50mm thick sound-absorbing cotton, and the outer layer is sprayed with anti-corrosion and anti-rust coating), and the noise reduction is up to 25dB;Electrical system protection grade IP24, can resist light rain, dust attack, adapt to -30 ℃~45℃ temperature range (low temperature models with oil preheating, coolant preheating function)

• Mobile and convenient design: Small and medium-sized units can be optionally equipped with mobile trailers (with towing devices, support legs, and braking systems), with a maximum traveling speed of ≤60km/h, facilitating outdoor operation and relocation. Large-scale units can be customized with containerized design (including sound insulation, heat dissipation and fuel tank) to achieve "immediate installation and use".

4. Fuel and lubrication optimization

• Fuel system: It adopts three-stage fuel filtration (coarse filtration + fine filtration + oil-water separator), with a filtration accuracy of 10μm, to prevent impurities from entering the engine and causing wear.The fuel tank adopts anti-corrosion design, the capacity supports 8-24 hours full load operation, and the external large capacity fuel tank can extend the power supply time.

• Lubrication system: use special long-acting oil (oil change cycle 800-1000 hours, 50% longer than ordinary oil), equipped with oil pressure warning device, automatic alarm stop when the oil pressure is lower than 0.2MPa, protect the engine from dry friction damage.

5. Safety redundancy design

• Startup redundancy: Parallel startup of dual batteries (2×12V for 12V models and 2×24V for 24V models) to prevent startup failure caused by a single battery being discharged. Large units are equipped with air-start backup systems, which can still start normally in extreme circumstances.

• Protection mechanism: It is equipped with 7 protection functions including overload, short circuit, overvoltage, undervoltage, high water temperature, low oil pressure and overspeed. When any parameter exceeds the standard, the machine will stop immediately to prevent damage to the unit. The derivative models of biogas/gas turbine units have an additional explosion-proof design (Ex dⅡB T4 grade) to adapt to flammable and explosive environments.

Usage Method (Standard Operating Procedure)

1. Pre-startup inspection (Daily mandatory)

2.Startup operation (automatic/manual mode)

(1) Automatic mode (recommended, adapted to emergency scenarios)

1. Switch the controller knob to "Auto" mode, ATS automatically monitors the mains voltage;
2. When the power supply is interrupted, ATS triggers the start signal of the unit, and the unit starts after preheating (30-60 seconds in low temperature environment), and the speed gradually rises to 1500r/min;
3. After the controller confirms that the oil pressure (≥0.3MPa) and water temperature (gradually rising to 70℃) are stable, ATS automatically switches the load to the unit power supply, and the loading process is smooth (avoid impact).

(2) Manual mode (adapted to debugging and maintenance scenarios)

1. Switch the controller to "manual" mode, and press the "preheating" button (preheating is required for low temperature environment);
2. Press the "Start" button after the preheating is completed, observe the speed, oil pressure and voltage parameters after the unit starts, and manually close the generator output switch after it is stable (about 3-5 minutes);
3. Gradually load the load. The initial load should not exceed 50% of the rated power. After running for 30 minutes, it can be raised to full load (when starting under heavy load, loading should be done in stages, with each loading not exceeding 30%).

3. Operation Monitoring (Daily Management)

• Real-time monitoring: check the controller display every hour to ensure that the voltage (380V±5%), frequency (50Hz±0.5Hz), water temperature (≤95℃), oil pressure (≥0.2MPa) and load current (not exceeding the rated current) are normal;
• Record-keeping requirements: Record daily power generation, fuel consumption, and operation duration, and establish maintenance files.If abnormal parameters are found (such as sudden rise of water temperature and sudden drop of oil pressure), immediately unload and stop the machine, and restart after troubleshoaking.

4.Shutdown operation (during mains power restoration/maintenance)

1. Unloading shutdown: after the mains power is restored, ATS automatically disconnects the unit load and switches to mains power supply; When manually shutting down, the load should be gradually unloaded (reduced to 0) first, and the generator output switch should be disconnected.
2. Cooling operation: Keep the unit running unloaded for 3 to 5 minutes (to cool down the engine and prevent component damage caused by high-temperature shutdown);
3. Shutdown completion: Press the "Stop" button. After the unit stops, close the fuel valve (in case of long-term shutdown) and disconnect the power supply of the controller. Clean the dust and debris on the surface of the unit and check for any leakage marks.

Safety and Protection (Core Specifications)

1. Installation safety (Basic requirements)

• Site selection standards: The unit should be installed in a well-ventilated area away from open flames and flammable and explosive items (at least 10 meters from fire sources), and the ground load-bearing capacity should be no less than 1.2 times the weight of the unit (for example, for a 1000kg unit, it should be no less than 1200kg/㎡). For outdoor installation, a rain shelter should be built (to prevent direct rainwater from washing), and for indoor installation, a maintenance space of no less than 1.5 meters should be reserved.

• Electrical safety: The grounding resistance of the unit is ≤4Ω (galvanized flat steel is used for grounding, and the grounding electrode depth is ≥2 meters).The generator output line should match the cable section (such as 100kW, ≥50mm² copper cable) to avoid overload and heat;Grid-connected protection devices (anti-islanding, over-voltage protection) should be installed when connecting with the mains power grid, in line with the grid access specifications.

• Fire protection configuration: the installation area is equipped with 2 4kg dry powder fire extinguifiers (ABC type), fire sand tank (volume ≥0.5m³), and set warning signs of "no open flame" and "beware of electric shock"; When the fuel storage capacity is ≤100L, it can be stored nearby. If it exceeds 100L, a separate explosion-proof fuel tank room should be set up (at least 5 meters away from the unit).

2. Operational Safety (Personnel Norms)

• Certified to work: Operators must undergo professional training from Kecheng, be familiar with the structure of the unit and operating procedures, and pass the assessment before obtaining a certificate to work. Unlicensed personnel and those who have drunk alcohol are strictly prohibited from operating the unit.

• Operating contraindications: Do not disassemble the fuel pipeline, electrical components, and exhaust pipe when the unit is in operation (high temperatures can cause burns). Smoking and the use of open flames are prohibited near the unit. When adding fuel, the machine must be shut down and the unit should be cooled down before proceeding (to prevent the fuel from igniting due to high temperatures).

• Personal protection: Wear work clothes and anti-slip shoes during operation. Wear insulating gloves and goggles during maintenance. When touching high-temperature components (such as exhaust pipes and water tanks), heat-resistant gloves should be worn to avoid burns.

3. Maintain safety (regular inspection)

• Power and fuel cut-off: Before maintenance, the main power supply of the unit should be disconnected (close the circuit breaker), the fuel valve should be closed, and the residual pressure in the fuel pipeline should be released (open the vent valve). Hang a warning sign that reads "Under maintenance, Do not start" to prevent others from operating it by mistake.

• Component maintenance: When changing the engine oil and filters, wait until the unit cools down to below 60℃ (to avoid scalding by hot oil). When overhauling the electrical system, a voltage tester should be used to confirm that there is no electricity before commencing work. When cleaning the scale in the cooling system, it is strictly prohibited to use highly corrosive cleaning agents (citric acid solution is recommended).

• Regular inspection: Check the battery voltage (to avoid undercharging), belt tension and fuel filter once a month. Change the engine oil and oil filter every 500 hours. Replace the air filter and fuel fine filter every 1,000 hours. Every year, Kecheng engineers are invited to conduct a comprehensive performance test (such as engine power and generator insulation resistance) once.

4. Emergency Response (Sudden Situations)

• Overload/short circuit of the unit: Immediately disconnect the generator output switch, shut down the machine to check the load condition (whether there are short-circuited or overloaded devices). After eliminating the fault, reduce the load and restart (the load during the first start-up should not exceed 50%).

• Fuel leakage: Shut down the machine and close the fuel valve. Use oil-absorbing cotton to clean up the leaked fuel. Do not switch on or off electrical equipment (to avoid spark ignition).Check the leakage points (such as pipe joints, valves), and test the tightness after repair (smear with soapy water, no bubbles are qualified).

• Fire accident: immediately stop the machine and cut off oil, use dry powder fire extinguisher to extinguishing the fire (no water is allowed to extinguishing the fire, fuel floating on the water will expand the fire); When the fire is large, call 119 and evacuate people to a safe area. After extinguishing the fire, investigate the cause of the fire (such as electrical short circuit or fuel leakage), and repair it before it can be used again.

• Low-temperature start failure: Check the battery voltage (charge if insufficient), replace the low-temperature engine oil (such as 15W-40) and antifreeze (concentration ≥50%), and activate the engine oil preheater and coolant preheater (preheat for 30-60 minutes). If it still cannot be started, check whether the starting motor and fuel injectors are functioning properly.