The main component of a generator can be broadly classified to as follows;
– engine
– Alternator
– fuel system
– Voltage regulator
– Cooling and exhaust system
– Lubrication system
– battery charger
– control panel
– Main / frame assembly
Engine
The engine is the source of the mechanical energy that is fed to the generator. The size of the engine is directly proportional to the maximum output power at the generator.
There are a number of factors that need to be taken into account while evaluating a generator engine. The engine manufacturer should be consulted to obtain complete specifications, engine operation and maintenance schedules.
Fuel Type Used – Generator engines operate on a variety of fuels such as diesel, gasoline, propane. (In liquid or gas form) or natural gas Small engines usually run on gasoline, while larger engines run on diesel, liquid propane, propane gas, or natural gas. Some engines can also run on dual fuel, both diesel and gas, in a double fuel mode.
Alternator
An alternator, also known as a ” genhead ”, is a part of a generator that produces power from a mechanical input provided by an engine. It consists of the assembly of moving and moving parts encapsulated in the machine. The components work together to induce a relative motion between the magnetic and electric fields, which in turn generates an electric current.
Fuel system
Typically, the fuel tank has enough capacity to keep the generator running for an average of 6 to 8 hours.In the case of a small generator, the fuel tank is part of the generator’s skid base or is fitted. On top of the generator frame For commercial applications it may be necessary to build and install an external fuel tank.
The typical features of the fuel system are the following:
– Connecting the pipes from the fuel tank to the engine The supply line carries the fuel from the tank to the engine and the return line carries the fuel from the engine to the tank.
– Exhaust pipe for oil tank The fuel tank has a vent hose to prevent pressure or vacuum build-up during filling and draining from the tank. When you fill up with fuel, make sure there is a metal-to-metal contact between the nozzle and the fuel tank to avoid sparks.
– overflow connection from the fuel tank to the drain hose This is necessary so that the overflow during tank filling does not spill liquid on the generator set.
– fuel pump It is the fuel transfer from the main storage tank to the day tank. The fuel pump is typically electric.
– fuel water separator / fuel filter This separates water and foreign matter from the liquid fuel to protect the other components of the generator from corrosion and contamination.
– fuel injector Atomizes the liquid fuel and inject the required amount of fuel into the engine’s combustion chamber.
Voltage regulator
This component controls the generator output voltage. It is a cycle voltage regulation process. Until the generator starts producing an output voltage equivalent to being able to operate at full As the generator output increases, the voltage regulator produces less direct current. When the generator is fully operational, the voltage regulator will go into equilibrium and produce sufficient DC current to maintain the generator output in full operation.
Cooling and exhaust systems
– Cooling system Continuous operation of the generator heats the components. It is essential to have a cooling and ventilation system to extract the heat generated in the process. Sometimes raw / fresh water is sometimes used as a coolant for the generator. But they are mostly limited to situations such as small generators in urban use or very large units of 2250 kW or more. Sometimes hydrogen is used as a coolant for the stator windings of large generators. As it is more efficient at absorbing heat than other coolants, hydrogen removes heat from the generator and transfers it through the heat exchanger to a secondary cooling circuit with demineralized water as the lubricant. cold This is why large generators and small power plants often have large cooling towers next to them. For other common applications, both residential and industrial, standard radiators and fans are mounted on the genset and function as the primary cooling system.
** It is essential to regularly check the coolant level of the generator on a daily basis. The cooling system and raw water pump should be washed every 600 hours and the heat exchanger should be cleaned every 2,400 hours of generator operation. The generator should be placed in an open, well-ventilated area with sufficient fresh air. The National Electrical Code (NEC) requires that a minimum of 3 feet of space should be allowed on all sides of the generator to ensure that cold air flows freely **.
Exhaust fumes
The exhaust system emitted by the generator is the same as the exhaust. From diesel or gas-line engines and contain highly toxic chemicals that need to be handled properly. Therefore, it is imperative that a sufficient exhaust system is installed to remove the flue gas. This point cannot be emphasized enough, as carbon monoxide poisoning remains one of the most common causes of death in hurricane-affected areas, as people often don’t think about it until it’s too late.
Exhaust pipes are usually made of cast iron, ductile iron or steel. The muffler is usually attached to the engine with a flexible connector to reduce vibration and prevent damage to the generator exhaust system. It must be made sure that the generator exhaust system is not connected to any other equipment. In addition, the operation of the generator must be approved by local authorities or in accordance with local laws.
Lubrication system
Since a generator contains moving parts in the engine, it needs to be lubricated. To ensure durability and smooth operation for a long time The engine of the generator is lubricated with oil stored in the pump.
** The lubricant level should be checked every 8 hours of generator operation. Lubrication oil leaks should be checked and replaced every 500 hours of generator operation **.
Charge the battery
The battery charger keeps the battery of the generator charged by supplying a precise ‘float’ voltage.If the float voltage is very low, the battery will continue to charge low. If the float voltage is very high, it will shorten the life of the battery. Battery chargers are usually made of stainless steel to prevent corrosion. It is also completely automatic and does not require any adjustments or changes to any settings required.The battery charger’s DC output voltage is set at 2.33 volts per cell, which is the float voltage. Precise for lead acid batteries The battery charger has a separate DC voltage output, which will interfere with the normal operation of the generator.
Control panel
– electric start and shutdown Auto-start control panel, automatically starts your genset during a power outage, monitors the generator while running and automatically shuts down when no longer needed.
– engine gauges Different gauges indicate important parameters such as oil pressure, coolant temperature. Battery voltage, engine rotational speed And working period The constant measurement and monitoring of these parameters allows the built-in generator to be turned off when they cross the relevant threshold level.
– generator gauge The panel also has a meter for measuring the output current and voltage, and the operating frequency.
– Other controls, phase selector switch, frequency switch and engine control switch. (Manual mode, automatic mode) and more.
Main / frame assembly
Portable or stationary generator Every unit has a custom case that provides a structural support base. The frame also allows grounding for safety.