Caterpillar C175 Diesel Generator
The C175 family of diesel generator sets offers the most power you can get in any single high-speed package: 2-4MW.
One of the most significant components in the development of the C175 was the integration of ACERT™ Technology into the engine platform.
ACERT Technology is a synergistic approach utilizing a suite of complementary building block technologies that can be individually adapted to accommodate a specific application. In recent years, Caterpillar has spent more than $1 billion on the development of clean diesel technologies. Today, more than 330,000 engines are currently in operation with ACERT Technology, accumulating more than 2 million hours of use each day.
With the C175, the building blocks of ACERT Technology have been tailored to meet the current and pending emissions requirements of stationary diesel generator sets in a variety of applications.
Thousands of hours of customer research created the foundation for the C175 design concept.
Some of the major advantages of the C175 family include:
- Proven Reliability with platform based on industry standard Cat® 3500 series, and supported by thousands of hours of lab and field-testing.
- Wider Power Range including 2000kW to 4000kW @ 1500 and 1800 rpm.
- Power Generation at Higher Speed than traditional medium speed products in the same power range.
- Higher Power Density equals more output from a given engine displacement / footprint, resulting in lower installed cost.
- Complete Package including SR5 generators, EMCP3 package controls and package/remote radiator with flexible controls packaging options simplifies installation.
- Lower Emissions meet U.S. EPA Tier 2 standards with a line of sight to meet U.S. EPA Tier 4 and EU Stage IIIB emissions levels.
- Lower Maintenance Costs due to increased oil change intervals, longer life (durability) of components and longer top end as well as full overhaul periods.
- Lower Operating Costs due to lower brake specific fuel consumption than competitive products.
- Systems Integration. The C175 electrical system components are engineered to work together with a wide range of products such as Uninterruptible Power Supplies (UPS), Automatic Transfer Switches (ATS), switchgear, remote monitoring services and customer building SCADA systems.
- Extensive Product Support from a worldwide dealer network with 24/7/365 parts and service availability.
1. Fuel System
The new C175 engine features a Cat® Common Rail Fuel System designed specifically for this engine platform.
Full Control of Both Fuel Delivery and Fuel Pressure At Any Load or Speed results in superior transient response and block load acceptance, as well as shorter recovery time.
More Compact single camshaft that is used only to open the intake and exhaust valves. It features a simpler injection design with no pumping function necessary.
Improved Cold Start Capability uses higher pressures at low speeds and produces less smoke.
“Fluid Containment” Design. The high-pressure lines and rails are designed to provide outer concentric low-pressure containment. If a leak occurs in the high-pressure section, it leaks back to the outer low-pressure section and drains back to the tank.
Integrated Manifold or Monoblock offers a single point of connection to the engine, which eliminates leak paths while improving reliability.
Fuel Cooler Eliminated. Unlike the unit injector system, the Common Rail System used on the C175 does not require excess bypass fuel to cool the injector since injection pressure load is taken off the injector. The result is a reduction of heat generation in the return fuel and reduction in fuel flow rate by a factor of 4 when compared to the unit injector system. This eliminates the need for a fuel cooler in most cases.
Improved Fuel Filters. The C175 uses an eco-friendly fuel filter system. Instead of throwing away the whole canister, only the disposable non-metallic element inside the canister is changed.
Electronic Fuel Priming Pump is Engine Control Module (ECM)-controlled and offered as standard equipment. No manual effort is required to pump the fuel, so it’s more convenient and requires less operator effort.
2. Cooling System
The design philosophy for the Cat® C175 cooling system is to minimize heat rejection by cooling only the parts that require cooling.
Inlet-Regulated System. The C175 features an innovative design unique to Caterpillar. The system senses the temperature at the inlet and controls the output providing more consistent temperatures and better control of oil viscosity than an outlet-regulated system.
Electronic Fluid Temperature Controller regulates inlet temperature of the coolant and allows for troubleshooting without removing the thermostat. Improved diagnostics enable the operator to pinpoint a problem quickly, which increases reliability and uptime.
Integral Water Supply and Return Manifold are built into the engine block to minimize connection points and bolted joints. This design helps contain fluids and improves overall engine reliability and serviceability.
Two-Stage After-Cooler. The first stage is cooled by a jacket water circuit and the second stage has a two-pass separate circuit. The after-cooler is constructed with tube fin cores that are more robust compared to the traditional bar plate fin design. The tubes of the core can be cleaned without removing the core from the engine, and the core can be remanufactured. The tubes also have more surface area per volume and less pressure drop, resulting in more efficient cooling. This after-cooler design also minimizes the size of the SCAC circuit, thereby reducing the size of the radiator. The location of the first stage jacket water core provides protection from high air temperatures. These features improve the durability and reliability of the cooling system.
3. Air Management
Air management is one of the ACERT™ Technology building blocks used on the Cat® C175 engine.
Crossflow Head provides separation between both the intake and exhaust ports and manifolds. The outboard air manifold location eliminates re-heating of intake air by preventing heat transfer from the exhaust to the intake. This results in reduced charge air temperature and increased charge air density, enabling higher power density as well as reducing SCAC cooling.
Taller Head accommodates larger ports and helps direct a large amount of cool air into the cylinder with the least resistance, resulting in the best port performance of any engine in the world. The taller head also accommodates increased valve lift of 22mm compared to 18mm on the Cat 3500, further improving breathing.
Improved Breathing. The tall crossflow head results in a greater amount of cooler air in and out of the engine, which helps produce higher power ratings and lower emissions. This, along with lower air pumping losses, results in lower fuel consumption.
New Generation of Turbochargers designed specifically for the C175. Four single-stage turbochargers provide a higher pressure ratio in a single stage. The turbocharger includes a cast titanium impeller and an improved bearing system that provides a higher load-bearing capacity and greater reliability, while increasing efficiency by 5% and extending the component life when compared to traditional cast aluminum impellers.
4. Lube System
The C175 lube system features two piston-cooling jets per piston.
A large capacity oil pump pressure regulation valve allows the engine to maintain optimum oil pressure at all speeds, loads and throughout the life of the engine, ultimately increasing durability.
5. Core Engine Components
The components of the new C175 centerline engine are designed for higher strength, durability and compactness.
Crankshaft has a larger diameter to handle bigger loads. It is made of steel forged material and features induction hardened fillets and journals. Thrust plates are located at the rear end of the crankshaft to reduce motion inside of the coupling between the engine and generator.
Block is made of cast iron and provides increased strength and stiffness, and is lighter weight.
Mid-Support Liners provide stronger support to the liner and offer more efficient cooling by only cooling the top 25% of the cylinder liner. Mid-support liners allow for a smaller inside diameter of the combustion seal, as well as a higher position for the piston’s top ring. The result is reduced crevice volume, improved cooling and combustion efficiency, and reduced emissions. Mid-support liners allow the head bolts to be closer to the cylinder bore to minimize cylinder spacing and to create a more compact engine.
Cylinder Cuff is specially designed for improved durability. The ring of the “cuff” located at the top of the cylinder scrapes off carbon accumulation on the piston top end, preventing the carbon from polishing, scratching or seizing the liner. The cuff also helps reduce crevice volume beside the piston, resulting in lower emissions.
Cylinder Head is made of iron for added strength. The tall C175 head helps eliminate the external water manifold by returning the coolant to the cylinder block.
Head Gasket features a simplified two-piece (carrier seal and combustion seal) design, shortening service time, decreasing parts costs, and increasing reliability and durability.
Pistons and Rings feature increased oil flow to pistons for better cooling and higher power ratings. Rectangular piston rings provide a superior seal and less motion, resulting in less wear and longer life. Piston, rod and liner come out as one assembly, resulting in faster, easier service.
Connecting Rods. Large diameter fracture split connecting rods provide better alignment between the rod and cap, which eliminates the need for a special alignment procedure.
Bearings. Large main and rod bearings provide better seizure resistance and better tolerance of a wide range of oil temperatures. Larger rod bearing and main bearing are more scuff and seizure resistant.
6. Engine Management System
The Cat® C175 utilizes much of the ACERT™ Technology electronics experience gained on small-bore engines and employs many new improvements and technologies more useful on large bore engines. The C175 Engine Management System exploits the power of modern control technology to improve reliability, exceed customer expectations and accommodate future customer requirements.
Engine Control Module (ECM). C175 engine controls use the latest version of the ADEM™ A4 ECM to deliver 50 times the computing power of its predecessor. Specific benefits include monitoring over 30 points on the engine, driving up to 20 injectors, protecting the engine, communicating over 100 engine parameters to the customer, diagnosing and reporting on engine health. The ECM uses the latest advancements in ACERT Technology to improve engine performance while reducing emissions.
Engine Controls and Datalink. Three primary controllers are temperature control module, fuel high-pressure controller and ECM. These are connected to the engine J1939 datalink.
Rigid Wiring Harness. Metal enclosed rigid wiring harness system protects critical engine circuits from accidental damage, reducing service calls and increasing reliability.
Controls Packaging. The standard panel is a rear-mounted EMCP 3.1 with the option to upgrade to the EMCP 3.2 or EMCP 3.3.
Caterpillar is introducing the next evolution of generators, the SR5 Series, with the introduction of the C175 generator sets. The SR5 Series 1800 and 3000 frame generators have been designed specifically to work with the C175 engines. The structural design is matched to the C175 engine. Torsional and linear vibration analysis and testing have been performed to ensure durability.
The SR5 generator’s insulation system has been improved to meet insulation Class H. SR5 generators feature 2/3-pitch as standard on all low, medium and high voltage generators. SR5 generators have IP23 particle ingress protection.
Generator Set Packaging. The C175 uses a fusible coupling to connect the generator to the engine. All engines, generators and controls are tested individually prior to assembly. Once assembled, the entire generator set package is tested before shipping to dealers to ensure quality.
The versatility of the C175 makes it ideal for a variety of applications.
- Continuous – A continuous rating has a typical load factor of 70% to 100% with no limit on the number of hours per year. Typical peak demand is 100% of continuous rated kW for 100% of operating hours. Typical applications include base load, utility or co-generation.
- Prime – A prime rating has a typical load factor of 60% to 70% with no limit on the number of hours per year. Typical peak demand is 100% of prime rated kW with 10% overload available for emergency use for up to one hour in 12. Typical applications include industrial, pumping, construction, peak shaving or co-generation.
- Standby – A standby rating has a typical load factor of 70% or less with variable load for about 200 hours per year,with a maximum expected usage of 500 hours per year. Typical peak demand is 80% of the standby rated kW with power available for the duration of an emergency outage. Typical applications include building service standby or emergency standby.
- Load Management – A load management rating has a typical load factor of 100% of the prime rating for a maximum of 500 hours per year. Typical peak demand is 100% of the load management rating, with no overload available. Typical applications include base load or peak shaving.
SOURCE: Caterpillar C175
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