What Should be Noted when Operating an 800KVA Cummins Diesel Generator in Winter?

Nowadays, as the weather gets colder, the use of diesel generators will also be affected to some extent. For Cummins diesel generator sets widely used in data centers, hospitals, communication base stations, and industrial facilities, proper maintenance in winter is not only related to equipment life, but also directly related to power supply reliability in emergency situations. Dingbo is a diesel generator manufacturer with 19 years of production experience. Today, Dingbo will provide you with a detailed analysis of the key points to pay attention to for 800kva Cummins generator sets in winter.

The primary challenge faced by 800kva Cummins generator sets in winter is the difficulty of starting at low temperatures. When the ambient temperature is below 5 ℃, the viscosity of diesel increases, the fluidity deteriorates, the battery capacity decreases, and the starting motor torque decreases. These factors collectively lead to a decrease in the success rate of starting. How should we deal with this situation?

Measures to ensure proper operation of 800kva Cummins generator sets in winter

Choose suitable diesel fuel

Select the diesel grade based on the local minimum temperature. Generally speaking, 0 # diesel is suitable for environments above 4 ℃; -10 # diesel is suitable for environments above -5 ℃; -20 # diesel is suitable for environments above -14 ℃; -35 # diesel is suitable for environments above -29 ℃; -50 # diesel is suitable for environments above -44 ℃.

Selection and replacement of antifreeze

Freezing of the cooling system is one of the main reasons for damage to winter generator sets. Freezing not only causes the engine cylinder block to rupture, but may also damage critical components such as radiators and water pumps. Dingbo will share with you some anti freezing measures:

Use antifreeze that meets Cummins specifications and dilute it according to the manufacturer's recommended ratio. Regularly check the freezing point of the antifreeze to ensure that it is at least 10 ℃ below the local historical minimum temperature. It is generally recommended to replace the antifreeze every two years or after 4000 hours of operation.

Drainage of cooling system

For water-cooled generator sets, if antifreeze is not used, the cooling system must be completely drained after shutdown, including all cooling water in the engine water jacket, radiator, and pipelines.

Heating device installation

In extremely cold areas, a coolant heater can be installed to maintain the engine temperature above 15 ℃ and ensure quick start-up at any time.

At low temperatures, the viscosity of lubricating oil increases and its fluidity deteriorates, leading to insufficient lubrication and exacerbating engine wear.

Lubricating oil strategy:

Viscosity grade selection: Choose the appropriate SAE viscosity grade oil based on the ambient temperature. If the ambient temperature is below -10 ℃, it is recommended to use 5W-30 or 0W-40 fully synthetic engine oil; -10W-30 can be used from 10 ℃ to 20 ℃; 15W-40 can be used above 20 ℃.

Regular replacement: Replace the engine oil according to Cummins' recommended cycle, check the oil condition before winter, and replace it in advance if necessary.

Heater consideration: In extreme low temperature environments (below -20 ℃), it is recommended to install an oil heater to ensure good oil flow during startup.

Wax in winter diesel is prone to precipitate at low temperatures, causing blockages in filters and oil circuits, which is a common cause of generator operation failures.

Fuel system protection:

Fuel heating: Consider installing a fuel heater or using a fuel filter with heating function to prevent wax precipitation.

Oil storage management: Keep the fuel tank full enough to reduce condensation inside the tank; Regularly discharge accumulated water from the fuel system; Increase the frequency of fuel filter replacement during cold seasons.

In addition to hardware maintenance, winter operating habits of diesel generator sets also need to be adjusted accordingly:

Extended preheating time: After starting in winter, the unit should be operated at low load (about 30% rated load) for 5-10 minutes, and the load should be gradually increased when the oil temperature rises above 40 ℃.

Load management: Avoid significant load changes in a short period of time and give the engine and generator sufficient adaptation time.

Cummins diesel generator sets are known for their reliability and durability, but any precision equipment requires special attention in extreme environments. Winter maintenance is not a simple task list, but a systematic protective system. If you want to learn more information, please feel free to contact us at any time! Email: dingbo@dieselgeneratortech.com