More big steps for Coleman Powermate: Company unveils 10 new diesel-powered gen-sets from 20 to 200kW; additions to gaseous-fueled line

More big steps for Coleman Powermate: Company unveils 10 new diesel-powered gen-sets from 20 to 200kW; additions to gaseous-fueled line – Power Generation

Mike Mercer

Last winter, Coleman Powermate took its first step toward entering the commercial power generation market by forming its Industrial Division, which was established to target light commercial and industrial standby power applications. Recently the company took two more big steps by introducing a new series of 10 diesel-fueled PowerStation gen-sets ranging from 20 to 200 kW and expanding its existing line of gaseous-fueled PowerStation emergency backup gen-sets to include 35 and 45 kW packages.

“The power generation market has been hot in industrial applications,” said Brendan McCormick, vice president and general manager, Coleman Powermate. “We have already noticed a lot of excitement, interest and orders for these products. These are coming from companies that range from small business back-up units to telecommunication sites to the ag market.

“The just introduced diesel units are 100 percent new to Coleman,” added McCormick. “When we started the Industrial Division, we formed it with an eye on the residential and small business market segments. However, since that time we discovered there is an opportunity for Coleman to enter into the diesel marketplace. Our focus, for now, will be on the 20 to 200 kW market segment. This is where we want to develop our diesel and gaseous-fueled product line.”

Six diesel models are now available with outputs of 30, 40, 60, 75, 105 and 135 kW The remaining models will be available by the end of 2001 or the first quarter of 2002.

“The new diesel-fueled PowerStation systems are ideal for remote sites that do not have access to natural gas connections, as well as small businesses that cannot afford to be without power,” said McCormick.

When complete, the new line of diesel-fueled PowerStation systems will include 10 models with output ratings from 20 to 200 kW. The complete model line will include: the PM5020P, PM5027.5P, PM5030P, PM5040P, PM5060P, PM5075P, PM5105P, PM5135P, PM5150J and PM5200J, which are rated 20, 27.5, 30, 40, 60, 75,105, 135, 150 and 200 kW respectively. All of the gen-sets are 60 Hz units, with 50 Hz also available.

The PM5020P gen-sets are powered by 2.5 L, naturally aspirated three-cylinder Perkins D3.152 engines, as are the PM5027.5P gen-sets. The PM5030P and PM5040P gen-sets are powered by the 3.99 L, four-cylinder naturally aspirated Perkins 1004.4 engine. The PM5060P and PM5075P gen-sets are powered by turbocharged versions of the Perkins 1004.4 engine and the engine on the PM5075 gen-set includes air-to-water aftercooling.

The PM5105P and PM5135P sets are powered by the six-cylinder, 5.99 L, Perkins 1006.6T engine and the engine in the PM5135P includes air-to-air aftercooling.

The PM5150J and PM5200J gen-sets are powered by John Deere engines. The PM5150J uses the turbocharged 6081T while the PM5200J is driven by the 6081A turbocharged and aftercooled diesel.

The engine packages from Perkins come complete with ancillary engine components such as radiators, fans and fan guards all mounted to the engine. The engines are coupled to Newage generators. The gen-sets are mounted on top of double wall, UL-listed fuel tanks with capacities of 100 to 350 gal. This design allows the gen-set to run for at least 24 hours before triggering a low-fuel alarm. The standard product comes with a 24-hour run time configuration, a 12-hour run time tank is also available. The tanks are also designed as a catch basin for any liquids that may leak from the engine in the event of a failure.

The new PowerStation gen-sets use an UL-listed main line circuit breaker in a NEMA 1 enclosure for fast, secure electrical connection. To ensure reliable starting during extreme weather, all new models include a battery charger and a Kim Hotstart block heater as standard equipment.

The units are designed to withstand all–weather applications and feature corrosion-resistant, powder coat painted, aluminum enclosures designed and built in-house. The enclosures use vertical air discharge vents for engine exhaust and cooling air and as a result, the diesel PowerStation systems sound emissions are less than 75 dB(A) at 23 ft., according to the company

The diesel gen-sets are available with a complete digital control panel supplied by Basler and based loosely on the Basler DGC 1000 panel. The panel comes standard with high water temp and low oil pressure shutdown, Options can be added for functions such as low coolant level. Monitoring packages to sense over–speed or under–speed conditions and remote start systems are also available.

A remote annunciator board is also available that uses relay contacts that in the event of a problem with the gen-set, a signal can be sent out to the remote panel. The panel can be upgraded to include remote communications with a telephone or a cell phone line. With this option, the person has the capability to check system status.

Switchgear is not packaged with the set. Coleman has an agreement with ASCO for switches. “We are an OEM reseller of both the 165 series and the 300 series automatic switches from ASCO,” said McCormick.

The diesel units like the gaseous-fueled PowerStation products are designed for permanent installation in a standby emergency capacity. “We set up the diesel PowerStation product line to provide customers with everything they need right off the shelf ,” said Tony Weir, PowerStation product manager. “We are not going to offer several levels of product with various options.”

The diesel gen-sets will be assembled in Miami Fla., or Kearney, Neb.

The existing line of gaseous- fueled PowerStation gen-sets has now been expanded with the addition of the PM4035 and PM4045, 35 and 45 kW gen-sets. The new PM4035 and PM4045 gen-sets use many of the same components as the 25 kW PM4025 unit introduced last year. “The introduction of the diesel units and the addition of the two gaseous-fueled units more than doubles the existing product line,” said Weir.

The all-weather generators are designed to be installed behind a business and connected to an existing natural gas or propane line. “These products are targeted to light commercial building applications such as restaurants, gas stations and convenience stores,” said McCormick. “Many small businesses simply can not afford to lose customers and revenue when a power outage brings their operations to a screeching halt for several hours?”

The new PM4035 and P4045 PowerStation gen-sets feature a 4.3 L GM Powertrain Vortec V-6 engine governed to 1800 rpm. The engine, which is designed to run on LP or NG is sourced from IMPCO. The engine drives a Newage rotating field, four-pole brushless alternator through a flex disc coupling.

The engine fuel system contains components from a collaborative effort between IMPCO and Woodward. This includes the mixer and the electronic governor from Woodward. The ignition system is a Delco EST with electronic advance. The Cowl muffler is a critical grade unit. To ensure reliable starting during extreme weather, both new models include a tn-mode battery charger from Guest and a Kim Hotstart block heater as standard equipment.

The gen-sets are designed to be certifiable to South Coast Air Quality Management District standards, the company said. “This required us to make some allowances for a different exhaust system, fuel system and mounting locations for the electronics that control emissions components,” said Weir. “The partnership with IMPCO was a big help in developing these gensets. They are working to certify the engines as emission compliant with the EPA and CARB.”

To prevent cooling from becoming an issue, the PM4035 and PM4045 gen-sets are designed to operate at ambient temperatures up to 122[degrees]F. “To do this, we use an oversized cooling system,” said Weir The radiator for this system is sourced from Atlas Radiator.

Air filtration is through Donaldson filter systems, which are packaged on the engine by IMPCO. As on the diesel-fueled systems, the engine and generator are mounted on Lord vibration isolation mounts. The UL listed Cutler Hammer circuit breaker is also vibration isolation mounted on the 35 and 45 kW units and all the diesel models. The 35 and 45 kW units are packaged with circuit breakers standard.

The big difference between the PM4025 and the PM4035 and PM4045 is the use of a more basic approach using an industry standard analog meter package, McCormick said. The 25 kW unit used a digital system. “The perception is that if there are digital controls on a gen-set it comes across as over designed or too high tech,” said McCormick. “According to our market research, in this market segment 65 to 70 percent of the marketplace can use the basic control package and it is more than adequate. It is all customers want and need especially if they are cost sensitive.”

The auto start controller panel includes a voltmeter, ammeter, frequency meter from Hoyt. Also included is a Hobbs hourmeter and Datcon engine gauges for d.c. and oil and water temperature. In addition, the panel includes an AM/VM selector switch, lamp test button, a.c./d.c. field circuit breakers and LED indicators for low oil temperature, high water temperature, over-speed, overcrank and engine running.

All the transfer switches that Coleman offers for the 4035 and 4045 models are ASCO units designed to the UL-1008 standards for fast and secure electrical connections.

The gen-sets are housed in powder-coat painted steel enclosures that feature extra-wide lockable doors for easy and safe access to the equipment. The cabinet of the 35 and 45 kW unit is a little larger for the V-6 engine compared to the 2.5 L four-cylinder in the 25 kW unit.

“The unit is quieter than most systems of this size,” said Weir. “The new models include a critical grade exhaust muffler and the same design vertical air discharge vents for additional noise abatement.

“The sound level targets that we set our sights on are quite low. We used 75 dB(A) as a starting point and then worked to get that number lower. We were very happy with the 25 kW unit because it is very quiet (66 dB(A) at 7 m) and we wanted to replicate that with the rest of the product line. We want to make the quietest gen-sets possible and still meet the other performance goals and price points.”

All of the new diesel and gaseous-fueled gen-sets will be sold, installed and serviced through Coleman Powermate’s nationwide network of master representatives and their independent dealers.


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