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Standby Generator Maintenance Tips

Sep. 25, 2019

If you don’t know about how to maintain your standby generator intake system and exhaust system as well as AC generator, this article will guide you to learn more. As we know that regular maintenance of diesel generator can not only prolong the service life of the genset, but also improve the performance of the unit.

Intake system

I. The intake system is mainly composed of an intake duct and an air filter.

II. The air filter configured in the medium-high diesel generator set is a dry paper air filter. The filter has a resistance indicator to indicate the blockage of the filter element. The resistance indicator should be checked before each start up and running of the unit. The air filter should be replaced immediately when all colour signs are visible from the window. The replaced air filter should be disposed of and cannot be reused. When replacing the air filter, special care should be taken to prevent dust from entering the intake system.

 Exhaust system

The industrial heavy-duty muffler equipped with medium-high diesel generator set is an absorption muffler. The working principle of the muffler is to absorb noise by installing a sound-absorbing bushing inside the muffler, which has a wide frequency range of noise reduction. The exhaust back pressure values of the muffler and the exhaust pipe are added together to obtain the exhaust back pressure value of the whole system.

standby generator

Generator maintenance

Pre-operation check

I. Grounding: The generator is not grounded when it leaves the factory, and must be grounded properly according to the site regulations. Improper grounding and incorrect protection can result in damage to the generating set and even personal injury.

II. Reconnection: Most alternators can be rewired to adapt different output voltages. Before changing the voltage, check that other components are suitable for new voltages, such as power switches, current transformers, cables and ammeters, voltmeters, etc.

III. Insulation inspection

After installing the generator, first check the resistance of the coil. At this point, the automatic regulator should be disconnected, the rotating diode can be temporarily short-connected with wire, or disconnected first, and all control lines must be disconnected. Disconnect the wire between the midpoint and the ground and measure the impedance from the terminal to the ground with a 500V megger or similar instrument. The insulation resistance from machine to the ground should exceed 2MΩ. If the insulation resistance is less than 2MΩ, the coil must be dried.

Repair and maintenance tips

I. It is recommended that the user check and clean the main generator and all accessories regularly.

II. According to the generator data, the insulation performance of the coil is tested before the first use. If the generator is backed up, the insulation of the winding coil is detected every 3~6 months depending on the humidity of the storage place. In high humidity areas, it is recommended that the user install a heater in the generator to keep it dry when the machine is not in use, which will help reduce the generator's failure rate and ensure its normal service life.

III. The inside and outside of the alternator should be cleaned regularly, and the frequency of cleaning depends on the environment where the machine is located. When cleaning is required, follow these steps: Disconnect all power, wipe off all dust, dirt, oil, water and any liquid on the outside, and clean the ventilation net, as these things will enter the coil, causing the coil to overheat or break the insulation. Dust and dirt should be sucked up with a vacuum cleaner. Do not use blowing air or high-pressure water spray to clean.

IV. Incorrect installation, operation, maintenance or replacement of parts can result in serious injury or equipment damage. Service personnel must be qualified to work in electrical and mechanical services. Electric shock can cause serious personal injury and even death. When conducting electrical wiring, the user should avoid the wrong operation of direct connection between the ground and the neutral line of the generator.

Heater (optional)

Gen set heater type

I. Water jacket heater:  the genset is in standby state, when the mains voltage is correctly connected, it is used to automatically heat the unit coolant. When the temperature rises to about 45°C (settable), the heating is automatically stopped. Water jacket heater is required for units that may be in icing areas. The power supply of the unit water jacket heater is AC220V. When the generating set is running, be sure to stop the water jacket heater, otherwise the heater may be burned out. The matching heater for middle and high installation has designed with relevant control functions on the control circuit, and automatically cuts off the heater power when the power is turned on.

II. Anti-condensation heater: When the ambient humidity of the unit is large, an anti-condensation heater should be installed. The power supply is generally the unit start battery.

III. Air preheater: Its function is to heat the air entering the combustion chamber in order to increase the startup success rate when the diesel generator set is started. When the unit is running normally and the starting motor has exited, the air preheater will automatically stop working. The power supply of the air preheater is generally the unit start battery.

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