Heavy Duty Diesel Generator set

Kecheng heavy duty diesel generator sets made in China can provide reliable power supply solutions for high-load scenarios such as mines, large industries or data centers. This series of units adopts heavy-duty engines from Yuchai, Weichai, Cummins and other brands as the power core, combined with efficient generators and intelligent control systems. They can withstand heavy load impacts and support multi-unit parallel operation, adapting to continuous operation under harsh working conditions. The product supports customized power ranging from 300 to 2000 kilowatts and can provide special configurations such as high-voltage output, explosion-proof design or containerized integration to meet the specific technical requirements of different sites. The unit complies with relevant national standards, and its core components offer a quality guarantee of up to two years. It is a reliable choice for large-scale projects to achieve safe, stable and efficient power supply.

Application scenarios (Exclusive adaptation for heavy-duty units)

1. Large-scale industrial manufacturing scenarios

• Applicable scenarios: Automotive vehicle manufacturers (stamping production lines, welding robots), metallurgical plants (blast furnace fans for steelmaking, steel rolling equipment), chemical industrial parks (large reaction vessels, circulating water pumps)

• Core value: Withstand 3 times the rated starting current (compatible with heavy-duty motor equipment), preventing the unit from going out; Supports 24-hour continuous full-load operation (annual operation time ≥ 8,000 hours), ensuring that industrial production lines are not interrupted. It can be linked with the factory DCS system to achieve "load adjustment as needed" and reduce energy waste.

2. Mining and resource development scenarios

• Applicable scenarios: Open-pit mines (mining crushers, charging systems for mining trucks), underground coal mines (ventilators, drainage pumps, explosion-proof type required), non-ferrous metal mines (mineral processing equipment, smelting furnaces)

• Core value: Adopting explosion-proof design (Ex dⅡB T4), suitable for flammable and explosive environments in mines; The body is made of high-strength manganese steel (impact-resistant and corrosion-resistant), capable of withstanding the harsh working conditions of mine dust and vibration. Supports dual-fuel switching between fuel oil and heavy oil (optional), reducing the cost of fuel transportation in remote mines.

3. Large-scale data centers and energy bases

• Applicable scenarios: Super-large data centers (backup power for server clusters, requiring 10kV high-voltage output), photovoltaic/wind farms (backup power for energy storage, making up for intermittent power generation gaps), gas power stations (peak shaving backup units)

• Core value: The high-voltage output model (6kV/10kV) is compatible with the high-voltage power distribution system of data centers, reducing step-down losses. High power quality (voltage distortion rate ≤2%, frequency stability ≤±0.1Hz), protecting precision server equipment; Supports parallel connection of multiple units (such as five 400kW units working in tandem) to meet the expansion requirements of data centers.

4. Large-scale infrastructure and transportation hubs

• Applicable scenarios: Highway service areas (large charging piles, heating systems), port terminals (container cranes, loading and unloading equipment), railway hubs (emergency power supply and signal systems for high-speed railway stations), cross-sea Bridges (bridge lighting, monitoring systems)

• Core value: Resistant to "frequent start-stop + fluctuating load" (such as intermittent operation of quay cranes), the response speed of the unit is ≤1 second; It adopts containerized integration (including sound insulation, heat dissipation and fuel tank), which is suitable for rapid deployment on infrastructure sites. Supports operation in harsh environments (-30℃ to 50℃), ensuring power supply for remote infrastructure projects.

5. Municipal and public emergency scenarios

• Applicable scenarios: Urban emergency rescue (temporary power supply after major disasters, such as earthquakes and floods), urban sewage treatment plants (large aeration tanks, sludge treatment equipment), large sports venues (main and backup power supply for events, requiring high reliability)

• Core value: Large-capacity fuel tank (1000-5000L) + external fuel source interface, supporting continuous operation for 72 hours (no need for frequent refueling in emergency rescue); Rapid deployment capability (containerized models can be put into use within 6 hours of arrival); Link with the municipal emergency platform to remotely monitor the status of the units and enhance the efficiency of emergency response.

Product advantages (Core Competitiveness in Heavy-duty Scenarios)

Technical parameters (Heavy-duty models 300-2000kW subdivision)

Technical features (Customized Design for Heavy-duty Units)

1. Enhanced power system

• Engine optimization: Select heavy-duty engines from Yuchai YC6K (300-800kW), Weichai WP15 (800-1500kW), and Cummins QSK60 (1500-2000kW), and adopt: ① Reinforced pistons (wear-resistant alloy + chrome plating layer, extending service life by 50%); ② Turbocharged intercooling system (intake air temperature reduced by 40℃, intake air volume increased by 30%); ③ High-pressure common rail injection (with a pressure of 2000bar, more complete combustion and a 5% reduction in fuel consumption) is suitable for the "high power and high load" requirements of heavy-duty units.

• Generator technology: Brushless self-excited synchronous generator is adopted (high-voltage model is equipped with epoxy glass cloth tube insulation, temperature resistance grade H), voltage regulation rate ≤±0.5%, short-circuit withstand time ≥2 seconds (to avoid short-circuit damage under heavy load). The high-voltage models (6kV/10kV) are equipped with high-voltage switch cabinets (including vacuum circuit breakers and relay protection), which comply with the GB/T 13540 standard and are directly compatible with industrial high-voltage power distribution systems.

2. Heavy-duty structure is adapted to the environment

• High-strength body: The body frame is welded with 16Mn manganese steel (tensile strength ≥510MPa), and the surface is sprayed with zinc + anti-corrosion paint (anti-rust grade ≥10), which can withstand the impact, vibration and corrosion in mining and infrastructure scenarios. All electrical components of the explosion-proof model adopt the explosion-proof grade of Ex dⅡB T4. The biogas pipeline is made of 304 stainless steel (wall thickness ≥3mm), suitable for flammable and explosive environments.

• Extreme environment adaptation: Optimized cooling system (dual circulation water cooling + forced air cooling), capable of full-load operation at high temperatures up to 50℃ (independent heat dissipation of the cooling tower); It can be started at a low temperature of -30 ℃ (equipped with a "three-preheating" system of oil preheater, coolant preheater and fuel heater). Dust-proof design (the air filter adopts three-stage filtration: coarse filtration + fine filtration + high-efficiency filtration, with a filtration accuracy of 1μm), suitable for high-dust working conditions in mines.

3. Intelligent heavy-duty control system

• KCPLC-05 Dedicated Controller:

① Multi-unit parallel control: Supports parallel operation of 8 units, with a load balancing deviation of ≤5% (for example, when the total load of 5 400kW units is 2000kW, the load deviation of a single unit is ≤10kW), which is suitable for large-scale industrial expansion requirements.

② Overload protection: When the load is detected to be ≥110% of the rated power, it will automatically reduce the load (to prevent overload damage). When the load sudden change is ≥30%, quickly adjust the fuel supply (response time ≤0.5 seconds) to avoid speed fluctuations.

③ Industrial linkage: Supports Modbus/RBUS protocols, can be connected to factory DCS systems and municipal emergency platforms to achieve "remote start and stop, parameter monitoring, and fault push", suitable for unattended scenarios.

• Remote operation and maintenance platform: Through the "Kecheng Electric Heavy-Duty Operation and Maintenance Platform", the following is achieved: ① Real-time monitoring (over 30 parameters such as voltage, current, fuel consumption, water temperature, etc.); ② Fault diagnosis (automatically identify over 200 types of faults such as "high water temperature" and "low oil pressure", and push solutions); ③ Operation and maintenance reminders (automatically push maintenance notifications based on operating hours), reducing the difficulty of operation and maintenance for heavy-duty units.

4. Long battery life and safety design

• Fuel and range: Equipped with a large-capacity fuel tank of 1000-5000L (made of 304 stainless steel, anti-corrosion), it supports full-load operation for 48-72 hours. Customizable heavy oil fuel system (compatible with heavy oil with viscosity ≤180cSt), equipped with heavy oil heating, filtration and conveying modules, to reduce fuel costs in remote industrial scenarios; External oil source interface (DN50 flange), supporting connection with large oil storage tanks to achieve unlimited endurance.

• Safety protection: Equipped with 8 layers of protection including "overload, short circuit, overvoltage, undervoltage, high water temperature, low oil pressure, overspeed, and gas leakage (explosion-proof model)", the machine will immediately shut down and sound an alarm when any parameter exceeds the standard. The high-voltage model is equipped with "anti-islanding protection, overcurrent protection, and grounding protection", meeting the safety standards for high-voltage distribution. The fuel system is equipped with an emergency shut-off valve (which automatically closes in case of fire) and is linked with the smoke alarm.

5. Convenient deployment and maintenance

• Integrated design: The large and heavy-duty models adopt containerized integration (dimensions comply with road transportation standards and can be transported by flatbed trucks), with integrated generator sets, fuel tanks, cooling systems, and control systems inside. After arrival, they can be put into use simply by connecting cables and fuel pipes (deployment time ≤6 hours). Supports "modular design" (the engine, generator and control system can be disassembled separately), facilitating the maintenance and replacement of heavy components.

• Maintenance Optimization: Large oil capacity (for models with a capacity of 300-800kW, the oil capacity is 50-100L, and the oil change cycle is 1000 hours, which is 20% longer than that of ordinary heavy-duty units). The vulnerable parts (filters, belts) adopt standardized design (compatible with the original factories of Weichai and Cummins), and can be purchased locally. The fuselage is reserved with maintenance space (width ≥1.5 meters) to facilitate the operation of large maintenance tools.

Usage Method (Standard Operation for Heavy-duty Units)

1.Pre-startup inspection (carried out by professional operation and maintenance personnel, completed within 30 minutes)

2. Startup operation (available in low-voltage and high-voltage models, requiring cooperation between two people)

(1)Low-voltage model (380V/660V)

1. Preheating start-up: Switch the controller to "manual" mode and start the "three preheating" system (engine oil preheating, coolant preheating, fuel preheating). Preheat in a low-temperature environment for 30 to 60 minutes (engine oil temperature ≥20℃).

2. Start the unit: Press the "Start" button, observe the rotational speed (gradually increase to 1500r/min), oil pressure (≥0.3MPa), and water temperature (gradually increase to 70℃). After the parameters stabilize (about 5 to 10 minutes), close the generator output switch.

3. Loading process: Load in stages according to "industrial load priority" (first core equipment such as crushers/reactors, then auxiliary equipment). The initial loading should not exceed 50% of the rated power. After running for 30 minutes, gradually increase to full load (single loading should not exceed 20%).

(2) High-voltage models (6kV/10kV)

1. High-voltage preparation: Maintenance personnel A checks the high-voltage switch cabinet (confirming that the "grounding switch" is disconnected and the "circuit breaker" is open), and maintenance personnel B starts the preheating at the controller end.

2. Unit startup: Follow the same startup process as for low-voltage models. After the parameters are stable, maintenance personnel A operate on the high-voltage switch cabinet: close the "disconnector" → close the "circuit breaker" → observe the high-voltage voltmeter (6kV±5%/10kV±5%).

3. Grid connection operation (if required) : Through the "Grid Connection" button on the controller, the phase and frequency of the mains power are automatically detected. When the phase difference is ≤5°, grid connection is automatically carried out. After grid connection, the load is gradually loaded (load rate ≤80%).

3. Operation monitoring (24-hour uninterrupted monitoring)

• Real-time monitoring: Record key parameters once per hour: voltage (380V±5%/6kV±5%), current (≤ rated current), frequency (50Hz±0.1Hz), water temperature (≤95℃), oil pressure (≥0.2MPa), fuel consumption rate (deviation ≤5% of design value);

• Remote monitoring: Check the status of the unit through the "Kecheng Heavy Duty Operation and Maintenance Platform", set parameter threshold alarms (such as alarm when water temperature ≥98℃), immediately reduce load and shut down when an alarm occurs, and troubleshoot.

• Load Management: When industrial loads fluctuate greatly (such as during intermittent operation of mine crushers), assign dedicated personnel to be on duty to prevent sudden increases or decreases in load (single load change ≤30%), and manually reduce the load if necessary.

4. Shutdown operation (divided into normal shutdown/emergency shutdown)

(1)Normal shutdown

1. Hierarchical unloading: First shut down auxiliary equipment → then shut down core equipment → Load drops to 0;

2. Low-voltage model: Disconnect the generator output switch → Run the engine no-load for 5-10 minutes (to cool the engine) → Press the "Stop" button.

3. High-voltage models: Maintenance personnel A opens the "circuit breaker" → opens the "disconnector" → closes the "grounding switch" in the high-voltage switch cabinet, while maintenance personnel B stops the machine at the controller end.

4. Safety closure: Close the fuel valve (for long-term shutdown), disconnect the power supply of the controller, check for any leakage or component damage in the unit, and record the operation data.

(2) Emergency shutdown (in case of fault or danger)

1. Immediately press the "Emergency Stop" button of the unit (cut off the fuel supply and disconnect the output switch);

2. For high-voltage models, it is necessary to simultaneously open the "circuit breaker" and close the "grounding switch" in the high-voltage switch cabinet.

3. Troubleshoot (such as high water temperature → Check the cooling system, gas leakage → start exhaust). Only restart after the faults have been eliminated.

Safety and Protection (High-Risk Control of Heavy Machinery Units)

1. Installation safety (in compliance with industrial safety standards)

• Site selection and layout:

① The installation area should be far away from open flame sources (≥20 meters) and densely populated areas (≥50 meters). The ground load-bearing capacity should be ≥ 1.5 times the weight of the unit (for example, for a 20,000kg unit, it should be ≥ 30,000kg /㎡, with a reinforced concrete foundation and a thickness of ≥500mm).

② The installation of high-voltage models must comply with GB 50060 "Code for Design of 3-110kV High-Voltage Switchgear Installations". The distance between the high-voltage switch cabinet and the unit should be no less than 2 meters. A safety fence (with a height of no less than 1.2 meters) should be set up, and a "High Voltage Danger" sign should be hung.

③ The installation area of explosion-proof models should have good ventilation (with an hourly ventilation volume of no less than 30 times the volume of the unit), and be equipped with a gas leakage alarm (with a sensitivity of no more than 0.1% VOL), which should be linked with the exhaust system.

• Electrical safety:

① The grounding resistance of the low-voltage model is ≤4Ω (using galvanized flat steel, grounding electrode depth ≥2.5 meters, quantity ≥2 pieces). The grounding resistance of high-voltage models is ≤10Ω (independent grounding grid, with a distance of ≥5 meters from the low-voltage grounding grid).

② High-voltage cables should be laid in cable trenches (with sand and bricks) or through galvanized steel pipes to prevent mechanical damage. The cross-sectional area of the cable needs to be matched (for example, for 1000kW/10kV models, a copper cable of ≥70mm² is required).

③ It is equipped with a lightning protection system (lightning arrester, lightning arrester) to adapt to the frequent lightning environment in open-pit mines and infrastructure construction scenarios.

• Fire protection configuration:

① The installation area is equipped with 4 8kg ABC dry powder fire extinguishers (no more than 5 meters away from the unit), 1 fire sandpit (with a volume of no less than 2 cubic meters), and 1 fire hose (with a length of no less than 20 meters).

② The fuel tank is independently set up (at least 10 meters away from the unit), equipped with an anti-seepage pool (laid with HDPE anti-seepage membrane), and fitted with a liquid level gauge and an emergency shut-off valve.

③ Develop a fire emergency response plan and organize a fire drill once every quarter (with the participation of operation and maintenance personnel to master the fire extinguishing and evacuation procedures).

2. Operational safety (Professional personnel with certificates are on duty)

• Personnel requirements:

① Operators must hold the "High Voltage Electrician Certificate" and the "Special Equipment Operator Certificate" (exclusive for heavy-duty units), and pass the specialized training (16 hours) assessment provided by Kecheng Electric Power before taking up their posts.

② It is strictly prohibited for unlicensed personnel or those who have drunk alcohol to operate the unit. High-voltage operation requires the cooperation of two people (one person operates and the other supervises). Before operation, make sure the "Operation ticket" is correct.

③ When operating, wear high-voltage insulating clothing, insulating shoes and insulating gloves (with a withstand voltage level of ≥10kV), and use insulating tools (which have passed the withstand voltage test).

• Operating contraindications:

① When the unit is in operation, it is strictly prohibited to open high-voltage switch cabinets, disassemble explosion-proof components, or touch high-temperature parts (such as exhaust pipes, with a temperature of ≥500℃, which can cause burns).

② For high-voltage models, grid connection and disconnection must be strictly carried out in accordance with the "Operation ticket". It is strictly prohibited to pull the disconnector under load (to avoid arc burns).

③ When refueling or adding coolant, the machine must be shut down. Wait until the unit cools down to ≤40℃ before doing so. It is strictly prohibited to use plastic buckets for refueling (to avoid static electricity ignition). For explosion-proof models, it is strictly prohibited to replace the desulfurizer and filter during operation.

• Emergency response:

① High-voltage leakage: Immediately press the "Emergency Stop" button → Wear insulating equipment → Use an insulating rod to disconnect the high-voltage switch → Locate the leakage point (such as cable damage), and after repair, use a megohmmeter to measure the insulation resistance. Only after it is qualified can the machine be restarted.

② Fuel leakage: Shut down the machine → Close the fuel valve → Start the exhaust system (explosion-proof model) → Clean the leaked fuel with oil-absorbing cotton and fire-fighting sand → Check the leakage point (if the flange gasket is damaged, replace it), and only start the machine after confirming there is no leakage.

③ Fire accident: Shut down the machine → Use dry powder fire extinguishers to put out the fire (do not use water to extinguish fuel fires) → Call 119→ Evacuate people in the surrounding area → Activate the emergency response plan (such as cutting off power supply in the surrounding area and isolating flammable materials).

3. Maintain security (executed by a professional team)

• Preparations before maintenance:

① Disconnect the main power supply of the unit (both low-voltage and high-voltage switches are open), close the fuel valve, and hang a warning sign that reads "Under maintenance, do not start".

② For high-voltage models, the "grounding switch" must be closed. After confirming that there is no electricity with a voltage detector, maintenance can be carried out.

③ Prepare maintenance tools (insulating wrenches, high-voltage testing instruments, explosion-proof flashlights), spare parts (original Kecheng filters, sealing gaskets), and protective equipment (insulating gloves, goggles).

• Maintenance operation specifications:

①When changing the engine oil, it should be done after the unit has cooled down (≤40℃). The used oil should be recycled in a dedicated container (handed over to a qualified institution for processing, meeting environmental protection requirements).

②When maintaining high-voltage switch cabinets, the upper-level power supply should be disconnected. Use a 2500V megohmmeter to test the insulation resistance (≥100MΩ), and clean the contacts (polish them with fine sandpaper and apply conductive paste).

③When maintaining explosion-proof models, it is strictly prohibited to use tools that can produce sparks (such as steel wrenches; copper wrenches should be used instead). After maintenance, a gas tightness test should be conducted (apply soapy water to the explosion-proof surface; if there are no bubbles, it is qualified).

• Professional maintenance

①Complex maintenance such as engine valve clearance adjustment, generator insulation testing, and high-voltage relay protection calibration must be carried out on-site by the heavy-duty after-sales engineers of Kecheng Electric Power (once a year, free service).

②After maintenance, a "load test" (loading to 80% of the rated power and running for 1 hour) must be conducted. Only when the monitoring parameters show no abnormalities can it be put into operation.

Maintenance Cycle Table (Exclusive for Heavy-duty Models)