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Application Engineering – Liquid Cooled Genset Application Manual

Throughout the World people rely on Cummins Power Generation generator sets for their electrical power needs. Diesel and spark-ignited engine-powered generators for hospitals, banks, computer centers, shopping malls and private dwellings provide instant and reliable power solutions. Our Worldwide distributor network provides support to every stage of a project.

In these pages we show how our products are correctly applied to the power solution to ensure a reliable and trouble-free life. We detail load characteristics that affect generator size and system performance. We demonstrate calculation methods and design techniques that ensure the interface to the electrical and mechanical systems is correct.

Because knowledge of the load that is to be supplied is vital to correct system design, these documents give information on dynamic loads such as motor starting, non-linear and specialist loads such as medical equipment. They also promote an understanding of ratings and the effect of ambient and load conditions on generator performance.

Please read the Warranty Statement carefully before proceeding with any design or ordering materials or labor.

These documents are in PDF format. To view them, you will need Adobe Reader® software.

Chapter 1 – Introduction gives an overview of the content of this manual, important safety information and references to other application manuals.

Chapter 2 – Preliminary Design describes the initial considerations for the power generation project. Equipment and installation requirements vary depending on the situation and intended use of the power generation. Guidelines for generator power ratings lead to the appropriate choice of duty according to the load requirements, with information on the considerations that need to be made in the choice of location.

Chapter 3 – Electrical Load Impact on Generator Sizing explains various load types, their characteristics and their impact on generator set size, operation and equipment choices. The chapter helps the reader to understand how generator performance is affected by the applied load and how the load may be affected by the generator characteristics. The importance of the sequence of load connection is explained and illustrated.

Chapter 4 – Equipment Selection describes the fundamental parts of a generator set and related equipment; their functions, inter-relationships and criteria for choices. The chapter describes the construction and functions of the brushless alternator and the effect of choice of excitation systems on load acceptance and short-circuit performance. Engine governing, starting systems, controls and a range of accessories are discussed.

Chapter 5 – Electrical Design details the electrical installation design of the generator in various application scenarios; i.e., single generator set installations or paralleling applications, related electrical systems and their interface with the facility and load. Topics discussed include, electrical connections, circuit breakers and disconnectors, choosing a generator transformer, voltage drop calculations, leading and lagging power factor loads, and protection coordination.

Chapter 6 – Mechanical Design explains installation design and related mechanical systems and their interface with the facility. Topics include foundation and mounting, vibration isolation, exhaust, cooling, ventilation and fuel systems; noise reduction, fire protection and equipment room layout. The chapter also contains illustrated examples of correct ventilation and exhaust system layout in order to avoid recirculation and promote efficient cooling.

Chapter 7 – Checklists contains checklists for an overall project, installation of open and enclosed generator sets, pre-start-up and start-up stages. These lists help to ensure that a comprehensive project portfolio is established and that every stage in the project is completed.

Chapter 8 – Appendices contains an overview of GenSize – the Cummins Power Generation sizing software application and PowerSuite contents. Also included is a discussion of reduced voltage motor starting techniques and useful references to world voltage standards, formulae, codes and standards and a glossary of terms.

For information regarding your application contact your nearest distributor.

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