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Common Problems of Diesel Generator Sets

May. 16, 2019

1. Impact of different climatic conditions on the operation of diesel generator sets:


Dust and sand

Salt water and mist at the beach

The air contains corrosive gases such as sulfur dioxide.

2. The composition of the diesel generator set:

Diesel engine, AC generator, controller. Other components: base, base fuel tank, radiator, water tank, recoil pad, anti-speaker, silencer, sound attenuated enclosure and other components.

diesel generator set

3. How long to replace three filters of diesel generator?

Air filter: 1000 hours, the replacement cycle can be shortened in a different environment.

Fuel filter: 50 hours replacement for the first time , usually 400 hours later. If the quality of the diesel used by users  is not good and the replacement cycle is shortened.

Oil filter: 50 hours of replacement for the first time, usually replacement after 200 hours.

4. How to identify the authenticity of the engine?

Appearance: For professionals who are familiar with the engine, the authenticity of the engine can be distinguished by the appearance, color, and overall color difference of the engine.

Identification: The diesel engine has the corresponding brand logo label.

Nameplate resolution: The nameplate on the engine is marked with the engine number. The cylinder and oil pump also have corresponding codes. Call the original factory to confirm the code, you can know the authenticity of the power.

5. AC Generator IP introduction

I represents the grade to prevent the entry of solid foreign matter, the highest level is 6;

P stands for the level of water ingress prevention, the highest level is 8.

For example, protection class IP56, IP55, etc. (D.NJ Power generator protection level is IP56)

6. Alternator insulation level introduction

The insulation grade of the alternator is divided according to the heat resistance grade of the insulation material used, and is generally divided into 5 levels:

Class A 105 degrees

Class E 120 degrees

Class B 130 degrees

Class F 155 degrees

H class 180 degrees

The theater level of the D.N Power generator is Class H.


7. Noise level introduction

30 to 40 decibels is an ideal quiet environment. More than 50 decibels will affect sleep and rest. More than 70 decibels will interfere with the conversation and affect work efficiency. A long-term living environment with a noise of more than 90 decibels can seriously affect hearing and neurasthenia, headaches, and elevated blood pressure. If suddenly exposed to a noise environment of up to 150 decibels, the auditory organs will be acutely traumatized, causing rupture of the tympanic membrane and loss of hearing in both ears. In order to protect the hearing, the noise should be controlled not more than 90 decibels; in order to ensure work and study, the noise should be controlled not to exceed 70 decibels. To ensure rest and sleep, the noise should be controlled not more than 50 decibels.

8. The purpose of parallel operation of diesel generator sets

Expand power supply capacity

Improve power supply reliability and achieve uninterrupted power supply.

9. The role of ATS

ATS is a switch between two sets of switch contacts for mains power and power generation, one set for power generation, one set is for mains power. Automatic switching can be realized through the instruction of the controller.

10. Fuel consumption calculation

Fuel consumption (L/h) = diesel rated power (kw) X fuel consumption rate (g/kwh) / 1000 / 0.84 (The density of diesel 0# is 0.84kg/L)

11. Diesel generator set debugging steps

Diesel engine inspection---generator inspection- no-load debugging-loading debugging-filling commissioning report-cleaning site

12. Generators can be divided into several categories from energy

Nuclear, hydraulic, wind, firepower. The firepower is divided into coal, diesel, gasoline, gas, and biogas. The generators we operate now are mainly diesel generators. Diesel is divided into light diesel (0# diesel, commonly used in high-speed diesel engines) and heavy oil (120#, 180# diesel, commonly used in medium-speed diesel engines and low-speed diesel engines).

13. The main function of control system

With manual, automatic, test shutdown

With various security features

Memory of various faults in operation

LED fault display alarm

Display voltage, current, frequency, etc.

Can be connected to a computer, but the controller needs to have RS232, 485 port

control system

14. What happens when diesel generating sets are overloaded for a long time?

Genset is usually not overloaded during operation, but can withstand short-term overloads. If the overload time of the unit is too long (exceeding the rated power), Some conditions may occur.


Cooling system overheating

Generator winding overheating

Decomposition of lubricating oil concentration causes oil pressure to be too low

Genset life shortening

15. What happens if the unit load is too low?

If the unit is running at a low load for a long time, the water temperature rises less than the normal temperature, the viscosity of the oil is large, and the friction becomes large. The oil that should be burned in the cylinder causes a paint surface to form on the cylinder head due to heating. If the low load persists, blue smoke may appear, the paint surface of the cylinder head gasket needs to be removed, or replace the cylinder head gasket.

16. What should pay attention to when installing the exhaust system?

Generator set has its standard configurations, such as industrial muffler, flexible exhaust connection, and elbow. User can install exhaust system according to the supporting facilities provided by OEM manufacturer. However, you need to pay attention to the following points during installation:

1. Make sure the back pressure is lower than the maximum set (usually, not lower than 5Kpa.)

2. Fixed exhaust system to avoid transverse and longitudinal pressure.

3. Leave room for contraction and expansion

4. Leave room for vibration

5. Reduce exhaust noise

17. When the diesel engine temperature is too high, is it feasible to add cooling water immediately?

Absolutely not, you need to wait until the engine is naturally cooled to normal temperature before adding cooling water. If the cooling water is added to the diesel engine under the conditions of lack of water and is overheating, the cylinder head, cylinder liner, and cylinder block will be cracked due to the drastic change of cold and heat,  which will cause serious damage to the engine.

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