Index1. Assembly2. Control panel unit 3. Testing4. Operation5. Maintenance

ASSEMBLY

In assembly unit different parts of generators are assembled to make a generator.The main parts of a generator are : Engine Alternator Power control In assembly line these three parts of the generator are assembled together .Sudhir gensets use cummins diesel engines :

Diesel powered generator sets remain the numberone choice for standby and emergency power systems, worldwide. Able to start and assume load in less than 10 seconds, and rated load in a single step, Cummins diesel generator sets are the epitome of rugged dependability and reliable mechanical and electrical performance. Diesel generators are also well suited to utility peaking plants, Distributed Generation (DG) facilities, peak shaving (or peak lopping), and power management at large commercial or industrial sites.

Features and Benefits:As a mature technology, Cummins clean and modern dieselpowered generators offer these key benefits: Rapid product availability Proven reliability and low lifecycle costs High efficiency and operational flexibility High quality electrical performance Wellestablished service and fuel supply infrastructure Optional factoryintegrated exhaust aftertreatments reduce emissions for highhour use in environmentally sensitive locations.Our 7.5 kW to 25 kW air and liquidcooled diesel generator sets offer traditional rugged construction, durability, and reliability for applications range from nursing homes to wireless services, to prime power for remote or temporary sites.In the 35 kW to 500 kW range, our dieselfueled generator sets with PowerCommand offer a wide array of system features that can be tailored to your specific application, whether for standby or prime power.In the 600 kW to 2.7 MW range, our dieselfueled PowerCommand generator sets meet your most demanding standby or prime power applications.

Stamford alternator

StamfordElectricistheworld-renownedtransnationalElectricGroup,oneofthethree.TheuseofadvancedtechnologyintheUnitedStatesandEuropeproducesfrequencyACalternatorallovertheworlduntiltheenvironmentisthepoorestregion.Itsstrongmanufacturingandservicesupportcapabilityandreliablequalityaccessestothewidelyrecognizationoftheusersaroundtheworld.Atthesametime,thecompanylaunchedamassivedriveproductline,includingACelectricmotor,self-startingsynchronousmotorandDCmotor.Standardizationofthesecomponentscouldbecoordinatedwiththegearboxinordertoreceivepropertorque,speedandbraking.Thecompanyalsomanufactureselectronicsystemsfortheproductionoffullcontrol,manipulationandorientation.Stanford'selectricalpowergenerationequipmentinthefieldalsoplayedanimportantroleintheproductionofcompletelineoflow-voltageandmediumvoltageelectricalalternatorproducts.

Standardfeatures:voltageregulator,theregulationofstability,adjustmentofvoltage/lowfrequencyperformanceoftheprotection,three-phaseRMSdetection,runningparallel,over-excitationprotection,over-voltageprotection,EMIsuppressionfunctions.These generator are very heavy to lift up and to transport for this purpose a very special kind of lifting machines are used called EOT cranes or electric overhead travelling crane.EOT cranes:The most adaptable and the most widely used type of power driven crane for indoor service is undoubtedly the three motion EOT crane. It serves a larger area of floor space within its own travelling restrictions than any other permanent type hoisting arrangement.

As the name implies, this type of crane is provided with movement above the floor level. Hence it occupies no floor space and this can never interface with any movement of the work being carried out at the floor of the building.The three motions of such crane are the hoisting motion and the cross travel motion. Each of the motions is provided by electric motors.The above characteristics have made this type of crane suitable for medium and heavy workshop and warehouses. No engineering erection shop, machine shop, foundry, heavy stores is complete without an EOT crane.In a steel plant, rolling mill, thermal power plant, hydraulic power plant, nuclear power plant, this type of crane is considered indispensable. In short in all industries, wherein heavy loads are to be handled, EOT crane find its application.EOT Crane Parts:A EOT crane consists of two distinct parts 1. Bridge 2. CrabBridge:

The Bridge consists of two main girders fixed at their ends and connected to another structural components called the end carriages. In the two end carriages are mounted the main runners or wheels (four or more) which provide the longitudinal motion to the main bridge along the length of the workshop. The motion of the bridge is derived from an electric motor which is geared to a shaft running across the full span of the bridge and further geared to a wheel at each end. In some design separate motors may be fitted at each corner of the main bridge. The wheels run on two heavy rails fixed above the floor level along the length of the shop on two girders, called gantry girder.Crab:The Crab consists of the hoisting machinery mounted on a frame, which is in turn mounted on at least four wheels and fitted with suitable machinery for traversing the crab to and fro across the main girders of the crane bridge. Needless to mention that the crab wheels run on two rail sections fixed on the top flange of the main bridge. Thus the load hook has three separate motions, these being the hoisting, cross traverse of the crab, and longitudinal travel of the whole crane. Each motion is controlled independently of the other motions by separate controllers situated in a control cage or in a suitable position for controlling from the floor by pendent chains.The essential parts are:

1. End carriage 2 Nos2. Wheel of Bridge 2 Nos3. The bridge At least 4 Nos4. Crab (without auxiliary hoist) 1 Nos5. Hoisting machinery set 1 Nos6. Wheels of crab At least 4 Nos7. Bottom Block (without auxiliary hoist) 1 Nos8. Lifting hook 1 Nos9. Rail on the gantry girder for crane movement 2 Nos10. Rail on the bridge for crab movement 2 Nos11.Operators cabin 1 Nos

In sudhir gensets different diesel range of generators are manufactured ranges from 25 KVA to2250 KVA.The description of some siletnt diesel generator are given below: Specification sheet 12-20 kWe, 15-25 kVA Prime

Ready to use, silent, compact and light weightThe ready to use Cummins 'DXP series' DG sets are smaller and lighter than any other DG set in it's class, thus giving you the advantage of optimising your valuable space.

Environment friendly powerThe Cummins 'DXP series' base DG sets are available with the lowest noise levels in it's range and are CPCB certified for emissions compliance, thus offering you environment friendly power.

The genset powered by the reliable Cummins 'X series' diesel engine meets stringent exhaust emission tests as per MOEF norms without sacrificing fuel efficiency at normal operating loads.

Unmatched warrantyThe Cummins DXP series DG sets are backed by the industry aknowledged best-in-class comprehensive warranty on the entire package including rubber components.

Lowest operating costsAll elements of the Cummins DXP series DG sets are designed from the start to work together to maximize efficiency, even at part loads, thus offering you the advantage of lowest operating costs.

AlternatorStamford alternator from Newage, suitable for operation at 1500 RPM, 415 Volts, 0.8 pf (lag) suitable for 50 Hz, 3 phase, 4 wire system, conforming to BS 5000/IS 4722. The Alternator is brushless type, screen protected, revolving field, self excited, self regulated through an AVR. The alternator has the following features: + 1.0 % Voltage regulation (max.) in static conditions

IP: 23 Enclosure

Permissible overload of 10% for one hour in 12 hours of operation

Mounting arrangementEngine and alternator are mounted on a common MS fabricated base frame with AVM pads.

Control panelThe control panel is manufactured with 14/16 gauge CRCA sheet and is powder coated for a weather-proof, long lasting finish.

The control panel consists of following parts: 1. Standard engine instrumentation

2. Multi function meter which measures: Individual phase current (Amps)

Phase voltages (V)

Generator output frequency (Hz)

Engine water temperature (Deg.C)

Lube oil pressure (kg/cm2) and equipped with hour counter

3. MCB of suitable rating

4. Key switch

5. Push button (Starter)

6. LED: Battery charging alternator fail indication

7. Current transformers

8. Instrument fuses duly wired and ferruled

Others Fuel tank suitable for 8 hours of operation

One dry and uncharged battery with battery leads

Single source power assuranceThe rugged and reliable Cummins DXP series DG sets are unique, because all the major components the engine, alternator, control system and canopy are designed, manufactured and tested by Cummins India/ Channel partners (Powerica Limited). This, complemented by the largest customer support network in India, capable of providing round-the-clock service and spares support, offers you SINGLE SOURCE POWER ASSURANCE from the world leaders in power generation.

Standard scope:Engine: Cummins DXP series diesel generating sets, powered by Cummins X series engines, are rated at 1500 RPM and conform to ISO 8528 specifications. The engines are radiator cooled, four stroke and multi-cylinder, conforming to BS 5514/ISO 3046.

The scope of supply includes: Electrical starter motor 12V DC

Battery charging alternator

MICO fuel system with mechanical governor

Dual spin-on fuel filter

Spin-on full flow lub oil filter

Residential silencer

Dry type air cleaner

Recovery bottle

Shut-off coil with safeties for LLOP/HWT

Flywheel and flywheel housing

First fill of lube oil and coolant

Acoustic enclosureThe acoustic enclosure is made of 1.6/2 mm thick CRCA sheets and structural/ sheet metal base frame painted in Munsel green shade. The walls of the enclosure are insulated with fire retardant foam so as to comply with the 75 dBA at 1mtr sound levels specified by Ministry of Environment & Forest.

The enclosure has the following features: \Specially designed to meet stringent MOEF/ CPCB norms of 75 DBA @ 1mtr at 75% load under free field conditions

Single point lifting for easy handling at customer site

Designed to have optimum serviceability

Air inlet louvers specially designed to operate at rated load

Made on special purpose CNC machines for consistency in quality and workmanship

Powder coated for long lasting service life and superior finish

With UV resistant powder coating, can withstand extreme environments

Use of special hardware for longer life

Insulation material meets exacting IS 8183 specifications for better sound attenuation

Flush styling - no projections

Fluid drains for lube oil and fuel

Fuel filling point

Diesel generator set V28 series Lowest life cycle costV28 Series design features have made Cummins diesel, the standard for comparison of operating economy, reliability and long life. When all cost factors like initial purchase, fuel, lube oil, maintenance and overhaul are considered, the bottom line will show that this Cummins V28 series will deliver the lowest life cycle cost.

Heavy duty, durable and emission compliantCummins V28 series diesel engine comes with heavy duty features, optimum size camshaft, optimized turbo-matching, premium injectors and is yet compact in size with optimum power to weight ratio making it the obvious choice for your long-term power needs.

The gen set powered by the reliable Cummins V28 series diesel engine meets stringent exhaust emission tests as per MOEF norms without sacrificing fuel efficiency at normal operating loads.

Silent PowerCummins 600-625 kVA enclosures are so designed as to have optimum performance and serviceability over the complete operating range. The enclosures are compact and are designed for ease in maintenance. The powder coated enclosures are manufactured on latest CNC machines to ensure superior finish and durability.

AlternatorStamford brushless alternator Self-excited, self regulated

Class H insulation

Salient pole revolving field

Single bearing

Digital automatic voltage regulator

Accessories

Silencer suitably optimized to meet stringent sound emission standards laid down by MOEF/CPCB

Base rail with integral fuel tank (520 litres capacity) is provided with drain plug, air vent, inlet and outlet connection, level indicator, manhole etc.

Integral fuel tank of 926 litres capacity

2 x 12 V dry, uncharged batteries with connecting leads and terminals

Acoustic enclosure

Specially designed to meet stringent MOEF/CPCB norms of 75 dBA @ 1mtr at 75% load under free field conditions

Designed to have optimum serviceability

Air inlet louvers specially designed to operate at rated load even at 50 deg C air inlet temp.

Made on special purpose CNC machines for consistency in quality and workmanship

Powder coated for long lasting service life and superior finish

With UV resistant powder coating, can withstand extreme environments

Use of stainless steel hardware

Insulation material meets exacting IS 8183 specifications for better sound attenuation

Specification sheet 480-500 kWe, 600-625 kVA Prime

Single source power assuranceDesign, manufacture and testing of engine, alternator, enclosure and other accessories is done by Cummins India/ Channel partners (Powerica Limited) for that optimum performance integrity and is backed by countrywide product support network with single source responsibility for the entire package.

Standard scopeEngine: Cummins V28 series direct injection, water cooled engine, 12 cylinder, Vee, 4 stroke, rated at 1500 RPM, conforming to ISO 3046/BS 5514 has the following specifications:

The scope of supply includes: Cummins PT Fuel Pump

Cummins heavy duty injectors

Holset turbocharger, pulse tuned exhaust manifold, stainless steel exhaust flexible connections

Radiator or heat exchanger, coolant inhibitor,

Shell and tube type lube oil cooler

Full flow paper element filters - fuel, lube oil and by-pass

Dry type replaceable paper element air cleaner with restriction indicator

Flywheel housing & flywheel to suit single bearing alternator

Starting motor Electric, battery charging alternator

Electronic control panel with Electronic Governor (ECPG)

Engine protections (trip)

High water temperature

Low lube oil pressure

Over speed

Low coolant oil level (alarm)

First fill lube oil

Control panelPowder coated control panel manufactured with 14/16 gauge CRCA sheet provides: MCCB/ACB of suitable rating with overload and short circuit protection

Voltmeter and Ammeter with selector switch

KW/PF meters

Frequency meter

KWh meter

Indicating lamps for Load On and Set Running

Current transformers

Aluminium busbars of suitable capacity with incoming and outgoing terminations

Instrument fuses duly wired and ferruled

Optionals

EngineHeavy duty air cleaner, lube oil/coolant heater with thermostatic switch

AlternatorThermistors, PMG excitation, space heater Control panel: "Power Command control panel for micro processor based metering, monitoring & auto synchronising control system, AMF control panel, battery charger, remote/auto start panel, auto/ manual synchronizing panel, audio/ visual annunciation for faults

Control panel"Power Command control panel for micro processor based metering, monitoring & auto synchronising control system, AMF control panel, battery charger, remote/auto start panel, auto/manual synchronizing panel, audio/ visual annunciation for faults

OthersMobile sets with canopy

Reliable and durableCummins K50 series diesel engine with strong regrindable crankshaft, high strength connecting rod, low pressure fuel lines, STC (Step Timing Controls) injectors and high volume coolant system make K50 series generating sets, more reliable and durable. Engines have clocked millions of hours, operating on some of the worlds most demanding conditions. Current engines are upgraded with new technologies for more performance and economy. The ultimate proof of superior performance and reliability is the fact that Cummins entities itself source these engines from Cummins India for their worldwide market.

Unmatched warrantyCummins K50 series diesel engine generating sets are a truly cost effective solution to long term power need backed by industry best 2 years / 5000 hrs warranty for the entire generating set.

Cummins advantageSpecial features of Cummins K50 series engines like STC (Step Timing Controls) injectors, low temperature aftercooler, square cumbustion chamber, optimised turbocharging and precision heavy duty camshaft make these engines the ultimate in exceptional fuel efficiency all across the operating range.

AlternatorStamford brushless AC alternatorSeperately excited, self-regulated

Class H insulation

Salient pole revolving field

Single/double bearing

Automatic voltage regulator

PMG standard

Accessories

Silencer suitably optimized to reduce noise

Sturdy base rail

990 ltrs. free standing fuel tank

4 x 12 V dry, uncharged batteries with connecting leads and terminals

Control panelPowder coated control panel manufactured with 14 / 16 gauge CRCA sheet and provides

ACB of suitable rating with overload and short circuit protection

Voltmeter and ammeter with selector switch

KW PF meters

Frequency meter

KWh meter

Indicating lamps for Load On and Set Running

Current transformers

Aluminium busbars of suitable capacity with incoming and outgoing terminations

Instrument fuses duly wired and ferruled

Optionals

EngineHeavy duty air cleaner, lube oil/coolant heater with thermostatic switch

AlternatorSpace heater, RTDs, BTDs

Control PanelAMF control panel, battery charger, remote/ auto start panel, auto/ manual synchronizing panel, audio/ visual annunciation for faults PowerCommand Genset Controls The PowerCommand Control, is a micro processor based generator set monitoring, metering, protection and control system. It offers advanced levels of functions for reliability and optimum genset performance. An extensive array of integrated standard control and digital display features eliminate the need for discrete component devices such as the voltage regulator, governor control and protective relays. The control system has easy servicing capabilities that allow system parameters to be interrogated, monitored and adjusted with a PC.

Specification sheet 1000-1200 kWe, 1250-1500 kVA Prime

Single source power assuranceDesign, manufacture and testing of engine, alternator, enclosure and other accessories is done by Cummins India/ Channel partners (Powerica Limited) for that optimum performance integrity and is backed by countrywide product support network with single source responsibility for the entire package.

Standard scope EngineCummins K series direct injection, water cooled engine, 12 cylinder, 4 stroke, rated at 1500 RPM, conforming to ISO 3046 / BS 5514 has the following specifications:

The scope of supply includes:Cummins PT fuel pump

Cummins heavy duty STC injectors

Holset turbocharger, pulse tuned exhaust manifold, stainless steel exhaust flexible connections

Radiator or heat exchanger, coolant inhibitor,

Plate type lube oil cooler

Outboard aftercoolers

Full flow paper element filters - fuel, lube oil and by-pass

Dry type replaceable paper element air cleaner with restriction indicator

Flywheel housing & flywheel to suit single / double bearing alternator

Starting motor Electric, battery charging alternator

Electronic control panel

Cummins Electronic Governor (EFC)

Engine protections (trip)

High water temperature

Low lube oil pressure

Overspeed

Low coolant oil level (alarm)

First fill lube oil

FeaturesDigital governing

Digital voltage regulation

AmpSentryTM protection for true alternator O/C protection on PCC 2100/ 3100 for solo/ paralleling applications

Analog/ bargraph/ digital AC output metering

Battery monitoring system to sense and warn against a weak battery condition

Digital alarm and status message display

Genset monitoring : Displays status of all critical engine and generator set functions

Smart starting control system : Integrated fuel ramping to limit black smoke and frequency overshoot

Advanced serviceability

PowerCommand network capability (optional)

PowerCommand Paralleling Genset ControlsIn addition to the features described above, the PowerCommand control with digital paralleling features eliminates the need for separate paralleling control devices such as synchronizers and load sharing controls, and KVAR / power factor controls. Besides this, features like synchronizing*, including import/ export controls for paralleling with an infinite (utility/ mains) bus and the ability to control the load on the generator set when paralleled with utility or mains are also built into the PowerCommand control.* For utility synchronizing applications, please contact your local Cummins distributor.

Control panel unit

Genset Controllers

The Power Command Control, is a microprocessor based generator set monitoring, metering, protection and control system. It offers advanced levels of functions for reliability and optimum genset performance. The power command control with digital paralleling control devices such as synchronizers and load sharing controls, and KVAR / Power factor controls.

TESTING :TESTS AT MANUFACTURER'S WORKThe following tests shall be performed at manufactures works prior to packing anddispatch to site, in the presence of Project Manager/Consultant. A weeks notice shall begiven. Nothing extra shall be payable. If witness is waived off the contractor shall have tosubmit test certificate.On DG Seta. Maximum power load capacity.b. Maximum motor starting capacityc. Endurance test.d. Fuel consumption at full load, 50% load, 75% load and 25% load.On The Alternatora. High voltage tests on stator and rotor windings.b. Insulation resistance of stator and rotor windings.c. Temperature rise test.d. Stator voltage and current tests.e. Stator phase sequence check.On The Excitera. High voltage tests on stator and rotor winding.b. Insulation resistance of stator and rotor windings.c. Temperature rise test.d. Measurement of losses.On The Automatic Voltage Regulatora. Sensitivity test.b. Response time test.