Engineering Backup Power Supply Diesel Generator sets

The engineering backup power supply diesel generator sets by Kecheng from China is a practical choice for backup power generation equipment. The unit can start up rapidly within 15 seconds of a mains power outage, meeting the urgent requirement for continuous power supply at the construction site. Its design fully takes into account the complexity of the engineering environment, capable of withstanding three times the instantaneous impact load and featuring excellent dust-proof and water-proof performance, making it suitable for outdoor working conditions. The product strictly adheres to the national engineering electricity safety standards. The core components come with a warranty of up to 2 years, and the greater the power, the longer the guarantee. Whether it is municipal construction, infrastructure projects, industrial park construction or emergency repairs, this unit can provide stable and reliable temporary power support, effectively ensuring the progress of the project and the safety of electricity usage.

The sets cover three power ranges: small (20-100KW), medium (100-500KW), and large (500-1500KW)：

Application scenarios (Engineering backup dedicated Adaptation)

1. Small-scale municipal and maintenance projects (20-100KW)

• Applicable scenarios: Emergency repair of urban street lamps (temporary lighting/maintenance equipment), renovation of community pipeline networks (power supply for water pumps/cutting machines), maintenance of small roads (temporary backup for road rollers/pavers)

• Core value: Trailer-mounted design (20-50KW, weight ≤2000kg, towed by pickup trucks), put into use within 30 minutes of arrival; IP54 dust and water resistance, suitable for municipal construction dust/rain environments; It can last for 8 to 12 hours on a full tank, meeting the daily maintenance needs without the need for frequent refueling.

2. Medium-sized infrastructure projects (100-500KW)

• Applicable scenarios: Highway construction (mixing plants/box girder pouring equipment), urban subway construction (auxiliary power supply for shield machines/tunnel ventilation), rural water supply projects (pump station backup/pipeline pressure testing equipment)

• Core value: Withstand 2.5 times the starting current (compatible with mixing plant motors and auxiliary equipment of shield machines), avoiding start-up stalling; Strengthen the anti-vibration structure (the body frame is thickened to 8mm) to adapt to the bumpy transportation at infrastructure construction sites. Supports "multi-unit parallel connection" (such as two 200KW units working in tandem) to meet the demand for load expansion.

3. Large-scale engineering and key projects (500-1500KW)

• Applicable scenarios: Construction of cross-river Bridges (power supply for tower cranes and bridge erection machines), industrial park construction (commissioning of factory equipment/temporary production lines), water conservancy hub projects (backup for gate hoists and monitoring equipment)

• Core value: The high-voltage model (6kV) is directly connected to the high-voltage power grid of the project and is compatible with high-voltage equipment such as tower cranes and bridge erection machines. Modular integration (including fuel tank/ATS/control cabinet) shortens the on-site installation period to 4 hours. The explosion-proof model (Ex dⅡB T4) is suitable for flammable and explosive scenarios such as water conservancy and chemical industrial parks, and is safe and compliant.

4. Engineering Emergency Repair Scenarios (Full Power Segment)

• Applicable scenarios: Post-disaster road repair (power supply for excavators/loaders), pipeline rupture repair (backup for water pumps/welding equipment), engineering accident rescue (emergency lighting/rescue equipment)

• Core value: Quick startup (≤15 seconds), power supply upon arrival for emergency repairs, avoiding delays in the golden repair time; The IP65 waterproof model (large type) can be submerged for a short time (at a water depth of 0.5m), making it suitable for flood repair environments. Models ranging from 20 to 500KW are available with the option of "mobile lighthouse integration", which can meet both power supply and lighting requirements simultaneously.

5. Temporary on-site and field engineering (50-300KW)

• Applicable scenarios: Field exploration camps (domestic electricity/exploration equipment), border defense engineering construction (power supply for outposts/construction equipment), island infrastructure (wharf construction/seawater desalination backup)

• Core value: Can start at -30℃ low temperature (optional "engine oil + coolant" dual preheating), suitable for low-temperature outdoor environments; The fuel consumption rate is as low as 200g/(kW · h) (for medium-sized models), and the long-term on-site operation cost is controllable. Dust-proof design (with a high-efficiency dust filter screen at the air intake) to prevent sand and dust in the wild from damaging the engine.

Product advantages (Core competitiveness for engineering backup)

Technical parameters (Full power range: 20-1500KW)

Technical features (Specialized design for engineering backup)

1. Engineering-grade power and load matching

• Enhanced engine:

① Small models (20-100KW) : Yuchai YC4F adopts "thickened cylinder liner + wear-resistant piston ring", which is suitable for frequent starts and stops in engineering (no more than 10 starts per day).

② Medium-sized models (100-500KW) : Cummins QSL with "variable geometry turbocharger", low-speed torque increased by 30%, suitable for motor start-up in mixing plants;

③ Large-scale models (500-1500KW) : Weichai WP12 adopts "vermicular graphite cast iron cylinder block", with a tensile strength of ≥550MPa, capable of withstanding the inrush current of heavy-duty equipment such as tower cranes.

• Generator optimization:

① Low-voltage models (20-500KW) : Brushless self-excited generator with "strong excitation device", voltage establishment time ≤0.3 seconds, strong resistance to load shock;

② High-voltage models (500-1500KW) : The 6kV generator has an insulation class of H (with a temperature resistance of 180℃) and a short-circuit withstand time of ≥2 seconds, meeting the power consumption standards for high-voltage equipment in engineering.

2. Protective structures for harsh environments

• Dust-proof and water-proof design

① Small/Medium-sized models: The body adopts "double-layer sealing + 50-mesh high-efficiency dust filter screen", and the air inlet is equipped with a cyclone dust removal device (dust filtration efficiency ≥95%). IP54 protection can withstand the splashing of engineering rain.

② Large models: IP65 protection (the whole machine is sealed, and oil-resistant rubber strips are used at the joints). All electrical components of the explosion-proof model are of Ex dⅡB T4 grade. Explosion-proof sealed joints are used for cable interfaces, suitable for chemical and mining engineering.

• Anti-vibration and anti-corrosion:

① Vibration resistance: The body frame of medium and large-sized models is welded with 16Mn manganese steel (thickness 8-12mm), and key components (generator/water pump) are connected with elastic couplings, with a vibration transmission rate of ≤8%, adapting to the jolts of engineering transportation.

② Anti-corrosion: The surface of the machine body undergoes a triple treatment of "acid washing and phosphating + galvanizing + powder coating" (salt spray resistance test ≥1000 hours), which is suitable for the high-humidity and high-salt environment of water conservancy and coastal projects.

3. Engineering deployment and operation

• Portable deployment

① Small model (20-100KW) : Trailer-mounted with mechanical support legs (one-button expansion, adjustable support height), minimum turning radius ≤5 meters, suitable for rural engineering roads.

② Large models (500-1500KW) : Modular design (engine/generator/fuel tank divided into blocks), single module weight ≤5000kg, can be assembled on the construction site with a forklift, installation period ≤4 hours.

• Easy operation:

①The controller is equipped with an "Engineering mode" (a simplified interface that only displays core parameters such as voltage, current, and water temperature), allowing construction personnel to operate it after one hour of training.

② Large models are equipped with a "remote control box" (10-meter extension cord), which can be remotely started and stopped from the engineering operation room, avoiding the influence of on-site noise/dust.

4. Intelligent Engineering Monitoring and Protection

• Load monitoring: The controller monitors the load current in real time. When the load exceeds 120% of the rated load (for medium and large models), it automatically reduces the load to prevent engine overload damage. Supports "starting current limit" (setting 2-3 times the starting threshold), suitable for engineering motor loads.

• Fault protection:

① Basic protection: All models are standardly equipped with "high water temperature (shutdown at ≥95℃), low oil pressure (shutdown at ≤0.2MPa), overload (shutdown for 30 seconds under 120% load), undervoltage/overvoltage (shutdown at ±15% voltage)".

② Engineering-specific protection: For medium and large-sized models, new features such as "dust filter clogging alarm (pressure difference ≥5kPa), vibration over-limit alarm (acceleration ≥5g), and low fuel level alarm (≤10% capacity)" have been added to provide early warnings of faults in engineering scenarios.

• Data Recording: Large-scale models support "engineering log storage" (recording the number of starts, load curves, and fault codes). Data can be exported during project acceptance to trace the reliability of power supply.

Power Selection (Precise Matching for Engineering Scenarios)

1.Core selecting basis

2.Power recommendation for typical scenarios

Usage Method (On-site operation in engineering)

1.Pre-startup inspection (Key points for engineering scenarios)

2. Startup operation (engineering emergency priority)

(1) Small model (20-100KW, manual start)

1. On-site preparation: Park the trailer on a flat ground, extend the support legs (with the body level), and connect the load lines (ensuring there is no short circuit).

2. Startup process: Open the fuel valve → Controller "Manual" mode → Press the "Preheating" button in low-temperature environment (30-60 seconds) → Press the "Start" button → Observe the rotational speed (1500r/min±50r/min) and voltage (380V±5%).

3. Loading operation: After the parameters have stabilized for 3 minutes, gradually close the load switch (first add lighting/small load, then increase the motor load) to avoid excessive loading at one time.

(2) Large models (500-1500KW, manual/remote)

1. High-voltage preparation: Confirm that the "grounding switch" of the high-voltage switch cabinet is open → the "disconnector" is closed → conduct a voltage test to confirm there is no electricity (high-voltage voltage tester).

2. Startup process: Hydraulic startup → Engine speed rises to 1500r/min→ Check oil pressure (≥0.3MPa) and water temperature → Close high-voltage circuit breaker → Load in stages of "20%→50%→80%→100%" (with a 5-minute interval between each stage, suitable for heavy engineering loads).

3. Remote monitoring: Check the load current and vibration values through the extended control box or APP to ensure they do not exceed the standards.

3. Operation Monitoring and Shutdown (Engineering safety First)

• Real-time monitoring: Record every 30 minutes: voltage (380V±5%/6kV±5%), current (≤ rated current), water temperature (≤95℃), oil pressure (≥0.2MPa), dust filter pressure difference (≤5kPa); When the engineering load fluctuates greatly, shorten the recording interval to 15 minutes.

• Exception handling:

① Dust filter screen blockage: Shut down the machine for cleaning or replacing the dust filter screen (2-3 pieces should be prepared on site as backups).

② Overload: Immediately unload non-essential equipment and check the load lines (for short circuits);

③ Excessive vibration: Stop the machine and adjust the support legs (ensure the machine body is level), and check if the coupling is loose.

• Shutdown process:

① Unloading: Disconnect all load switches and reduce to no-load.

② Cooling: Run the engine idle for 5 to 10 minutes (to cool the engine/turbocharger);

③ Shutdown: Press the "Stop" button → Close the fuel valve (for long-term shutdown) → For high-voltage models, close the "ground switch" to discharge.

④ Project completion: Clean the dust filter screen, check the machine body for any bumps (the project site is prone to collisions), and record the operation log.

Safety and Protection (Engineering Site Specifications)

1. Installation safety (Exclusive for engineering sites)

• Site selection and arrangement:

① Install in the upwind direction of the construction area (to prevent dust from blowing towards the unit), away from open flames (≥15 meters) and flammable and explosive materials (≥20 meters). The distance between high-pressure models and the activity area of construction personnel should be ≥3 meters, and a safety fence (height ≥1.2 meters) should be set up.

② The ground load-bearing capacity should be no less than 1.5 times the weight of the unit (for example, for a 6000kg unit, it should be no less than 9000kg/㎡). The temporary site of the project should be paved with crushed stones and steel plates (to avoid subsidence), and steel plates should be placed under the support legs (with an area of no less than 0.5㎡/ leg).

③ High-voltage cable laying: Run through galvanized steel pipes (wall thickness ≥5mm), buried at a depth of ≥0.7 meters (to avoid being crushed by engineering vehicles), and the cable markings should be clear (to distinguish from other engineering lines).

• Electrical safety:

① Grounding system: The grounding resistance of low-voltage models is ≤4Ω, and that of high-voltage models is ≤10Ω. The grounding electrode uses galvanized Angle steel of ∠50×50×5 (length ≥2.5 meters), which is reliably connected to the grounding grid of the project.

② Load wiring: YCW heavy-duty rubber-sheathed cables (oil-resistant/wear-resistant) are used for temporary engineering circuits. The terminal blocks should be pressed tightly with copper lugs (to prevent loosening due to vibration). For motor loads, a neutral wire should be connected (protective zero connection).

③ High-voltage operation: For 6kV models, high-voltage insulating tools (insulating gloves/boots, voltage detector, with a withstand voltage of 10kV) must be provided. During operation, two people should cooperate (one person operating and one person supervising), and fill out the "High-voltage Operation Ticket".

• Fire Protection and Emergency Response

① The installation area is equipped with 2 8kg ABC dry powder fire extinguishers (no more than 5 meters away from the unit) and 1 fire sandpit (with a volume of no less than 2 cubic meters). Flammable materials (such as diesel drums and wood) are prohibited from being piled up around the unit at the construction site.

② Post warning signs such as "Engineering Backup Power Supply, non-operating personnel Prohibited from approaching" and "High Voltage Danger", and hang warning lights (red flashing) at night.

③ Develop emergency plans for power outages in the project (such as switching backup power in case of unit failure), and organize construction personnel to conduct drills every quarter.

2. Operational Safety (Engineering Personnel Specifications)

• Personnel requirements:

①Operators must hold a "Low Voltage Electrician Certificate" (for small models) or a "High Voltage Electrician Certificate" (for large high voltage models), and pass the specialized training (including equipment operation and fault detection) assessment conducted by Kecheng Engineering.

② When operating at the construction site, wear safety helmets, anti-slip shoes and work clothes. For high-voltage operations, wear insulating gloves/boots in addition. It is strictly prohibited to operate after drinking alcohol or when fatigued.

③ When the unit is in operation, do not approach rotating parts (fans, couplings), and do not open the dust filter screen/body panel (to avoid dust inhalation and high-temperature burns).

• Operating contraindications:

① Do not load when the unit is not stable (such as immediately connecting to full load after startup). Load gradually (20%→50%→100%).

② It is strictly prohibited to collide with the unit with engineering vehicles (such as excavators and loaders). When moving the unit, the machine must be stopped first and the support legs retracted.

③ It is strictly prohibited to operate high-voltage models during thunderstorms. The power supply must be disconnected and grounded for discharge to prevent lightning strikes.

④ Do not continue to operate when the dust filter is clogged (as it may cause the engine to overheat and pull the cylinder). It should be cleaned in time.

• Emergency response:

① Engine fire: Stop the machine immediately → Close the fuel valve → Use a dry powder fire extinguisher to put out the fire (do not use water to extinguish the fuel fire) → Evacuate the surrounding people.

② High-voltage leakage: Disconnect the upper-level power supply → Wear insulating equipment → Isolate the fault point with an insulating rod → Check the cable/terminal block (whether it is damaged or grounded);

③ Power outage for the project: If the unit fails to start, immediately switch to the backup power supply for the project (such as another unit), and check for faults (battery, fuel, starting system) to avoid affecting the construction.

3. Maintain safety (On-site maintenance of engineering projects)

• Preparations before maintenance:

① Disconnect the power supply of the unit (disconnect the main switch for low voltage and the circuit breaker and ground for high voltage), close the fuel valve, hang the warning sign "Under maintenance, do not start", and notify the construction site to suspend the relevant loads.

② Clear the debris around the unit (engineering dust, crushed stones), set up a temporary protective shed (in case of rain), and prepare maintenance tools (wrenches, dust filters, engine oil, spare parts);

③ Before maintaining large models, the pressure of the cooling system should be released (by opening the vent valve) to prevent hot water from spraying and injuring people.

• Maintenance operations:

① Daily maintenance: Clean the dust filter screen daily (blow compressed air at 0.2MPa from the inside out), check the engine oil/fuel level, and tighten the terminal blocks (which are prone to loosening due to engineering vibration).

② Regular maintenance: Change the engine oil/oil filter (using engineering-specific 15W-40 engine oil) every 500 hours, replace the air filter/fuel filter every 1000 hours, and check the engine valve clearance and generator bearings every 2000 hours.

③ Specialized maintenance for engineering: After rain, check the engine body seals (for any water seepage). Increase the frequency of cleaning the dust filter screen during dusty weather. If the engine is to be shut down for a long time (≥1 month), drain the fuel/coolant and apply anti-rust oil (to the engine block).

• Post-maintenance testing:

After the maintenance is completed, the unit needs to be started (run no-load for 30 minutes), check whether the parameters (voltage, current, water temperature, oil pressure) are normal, test the load switching function (such as ATS switching), and ensure the reliable power supply for the project before connecting the load.

Maintenance and Servicing Periodic Table (Exclusive for Engineering Backup)