Generator Training for New

personnel
Diesel Engine - Prime Mover

Turbocharger: exhaust driven air

pump supplies engine intake with air Air Cleaner
above atmospheric pressure

Charge Air Cooling:

Heat exchanger to cool the engine Fuel Injection Pump
intake air after it has been
with Mechanical or
compressed by the turbocharger.
Electronic governor.
Side by side with Radiator
Basic Engine Generator Set

Turbo Charger
Exhaust Outlet

•Converts Mechanical Air Intake Filter

Energy into Electrical
Energy Control Panel
•Engine Drives Alternator,
Resulting in Electrical
Power Output (AC) Radiator

• 1500 RPM Engine Speed

Gives 50 Hertz Electrical
Output Engine Output Circuit
Alternator Breaker
•Engine Power Capability is
Battery
Rated in Horsepower at
1500 RPM
Skid Base
Basic Engine Generator Set

Turbo Charger
Exhaust Outlet

Air Intake Filter

•Mechanical or Shaft Power

Control Panel
(kWm) of the engine equals
Horsepower times 0.746
kWm = HP x 0.746 Radiator

•Electrical Output Power

(kWe) equals mechanical kW
times Alternator Efficiency Engine Output Circuit
Alternator Breaker
kWe = kWm x EfficiencyAlt
Battery

Skid Base
General layout

Control panel

Engine

Hook-up

Load

Rad / Cooler Alternator Circuit breaker

Generator Set Components

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Engine

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
 Engine

•The main function of the engine is to provide mechanical energy at a

constant speed.
•The GOVERNOR controls the engine’s speed and power output.
•The engine’s constant speed provides constant electrical frequency
(Hertz) from the alternator.
•Maintaining Constant Frequency (no load to full Load):
Mechanical Governor: 3-5% or +/- 2.5% or 60 - 63 Hz
Electronic Governor: .25% or +/- .125% or 60- 60.15 Hz
 Engine Governors

Mechanical Governor:
•Fuel flow is controlled by
rotating weights operating
against a spring.
Mechanical Fuel Pump

Electronic Governor:
• Fuel flow is controlled by
an electronically actuated valve
Electronic Controller

Electronic Fuel Pump

Engine Efficiency

Three Basic Engine Configurations:

1. Naturally Aspirated,
30%Typical Efficiency

2. Turbocharged,
36% Typical Efficiency

3. Turbocharged & Inter-cooled,

42% Typical Efficiency
Generator Set Engine Ratings

Standby rating
• Unit is available for back up power
• Unit will operate only during power outages
• No overload capacity is available
• Engine life expectation is reduced

Prime rating
• Unit will operate frequently
• Unit has 10% overload capacity for short periods
• Engine life expectation is increased

Note: Rating is not about configuration, the same Generator Set

will have a prime rating and a standby rating. Ratings are subject
limiting ambient conditions of elevation and temperature. See
spec sheet or call factory for derate guidelines.
Engine Cooling System

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Engine Cooling System

•Air Cooled Radiator

Liquid coolant is circulated through the engine and radiator by the
water pump. Coolant picks up heat in the engine and rejects it in
the radiator, thus cooling the engine.
•Engine Driven Fan
Fan blows air through the coils and fins of the radiator, taking heat
away from the radiator. The fan is ‘pusher’ fan that brings air from
the engine side. Unlike your automobile which has a ‘sucker’ fan.
•LAT
Limiting Ambient Temperature is the the design point for the
cooling system. It is possible to operate above LAT but at reduced
engine performance.
•Temperature Derate
Calculation of performance reduction is possible if you know the
ambient temperature. See individual spec sheets for derate
calculations.
Alternator

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Alternator

Basic Components of the Alternator

Single-Bearing Alternator

Junction Box
Load Connection
Terminals

Main Stator
AVR

Main Rotor
Drive Disc

Exciter Stator
Bearing

Exciter Rotor
Rotating Diodes
Alternator

Cooling fan Alternator

AVR

Load

Excitation rotor
Main rotor

Excitation stator
Main stator
Rotating diodes
Automatic Voltage Regulator (AVR)

The AVR automatically controls the output

voltage from the generator set.

STABILITY ADJUSTMENT
VOLTAGE ADJUSTMENT

LOW SPEED PROTECTION

Typical Voltage Regulation: +/- 2.0%

IR’s Voltage Regulation: +/- 0.5%
AVR Location
Main Circuit breaker

Load

Main Circuit Breaker

- Trips instantaneously in the
event of short circuit or earth
leakage fault
-Trips after time period under
sustained overload
Hook-up to load

Load

Hook-up panel.
- Facilitates hard wire connection
- Socket panel also
to load.
available on many models
Control system

Control panel

Load
Control System Functions

The control system is the interface between the generator set and
the operator.

Functions:
• Starting / Stopping the generator

• Providing engine information

• Oil Pressure
• Coolant Temperature
• Battery Voltage
• Hour Meter
• Speed (RPM)
Control System Functions

The control system is the interface between the generator set and
the operator.

Functions:
•Providing alternator information
• Voltage (Line to Line & Line to Neutral)
• Current (Per Phase)
• Frequency (Hz)

• Diagnostics
•Dependant on panel / system design
 Generator Set Alternator Ratings

Heat Rise Rating

• Based upon the expected heat rise of alternator windings above
an ambient of 40°C
• When used for a standby application, higher heat rise ratings are
acceptable
• When used for a prime application, lower heat rise ratings should
be used
• Heat rise ratings give an expectation of life of insulation on the
windings
•Insulation materials are categorized by their ability to tolerate
effects of heat. Class H insulation is best.
We use only Class H Insulation

Note: The same Alternator will have different ratings at different heat rise
points. Example: Alternator model LSA432L7 is rated at 72kW @ 125°C rise,
66kW @ 105°C rise, and 78kW @ 150C° rise.
Important Takeaways

The governor controls The Automatic Voltage

the engine speed and Regulator (AVR)
mechanical output power controls the output voltage
Controller

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Controller
The control system is the MMI (man-machine interface) between
the generator set and the operator.

• Starts/Stops the engine

• Provides engine information
Oil Pressure
Coolant Temperature
Battery Voltage
Elapsed Time Hour Meter
Engine Speed (RPM)
• Provides alternator information
Voltage (Line to Line & Line to Neutral)
Current (Per Phase)
Frequency
• Protection
Diagnostics
Alarms
Faults (Shutdowns)
IR Intellisys™ Digital Controller

Information Display (LCD)

Power
Switch

Display
Function
Keypad

Information
Navigation
Keypad

Diagnostic
LEDs

Numeric Keypad Operating Mode Keypad

Control Panel

Intellisys Emergency Stop Button

Panel
Illumination
Light
Basic Control Panel: M150
Control and switchgear

4-position key switch

Lamp test push button

Panel fuse
Basic Control Panel: M150

Measuring Instruments

1 hour meter

1 ammeter + 4 position switch

1 voltmeter + 7 position switch

Basic Control Panel: M150

Operating lights

Front panel lighting

Over current
Low oil pressure
High coolant temperature
No-charge alternator
Fuel Tank/Fuel System

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
 Original style with Galvanised skid & Fuel tank part of base frame

Fuel tank / base frame

Skid
Containment style with deep bund. Fuel tank contained within bund

Deep
Bund
 Dual walled fuel tank arrangement

Mounting straps

Fuel tank

Containment base
3 Way Fuel Valve

This options enables the

operator to connect the
fuel tank with an external
source, providing for
extended operation time
Fuel Tank/Fuel System

Ingersoll-Rand IT Support Centre (UK)

G66 (60 kVA)

• Generator used as a standby unit

• Connected to the mains via an
Auto Transfer Switch (ATS).
• Fitted with an Auto-Start Package
& 3 Way Fuel Valve.
• Connected to an external ‘bunded’
fuel tank for extended run-time.
Enclosure

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Enclosure

Control panel

Load

Provides sound insulation, security and cooling

Enclosure

Sound Attenuated Weather Enclosure

•Protection from Elements
•Security
•Fits on Sub Base Tank
Accessories and Options

Alternator Engine
Fuel Tank /
Fuel System

Control System

Exhaust System

Accessories & Engine Cooling

Options Battery System
Charger Enclosure
Accessories and Options

•Block Heater
-Keeps the engine warm for quick starting
-Powered from utility source (shore power)
•Battery Heater
-For enhanced starting performance in cold conditions
-Powered from utility source (shore power)
•Anti-Condensation Heater
-Helps protect alternator windings from effects of
condensation and moisture
-Powered from utility source
Auto Transfer Switch (ATS)

Automatically switches the load from the

mains to the generator if the mains fails.
On return of the mains, it will automatically
switch the load from the generator to the
mains.

Remote, IP 54 rated, wall mounted cabinet.

Fuse protected auxiliaries (C/B >G130).

Incorporate status lamps to indicate:

•mains on load
•genset on load
Automatic Transfer Switches

Utility Source

Automatic Transfer
Switch (ATS)
•Senses presence of ATS-Generator
both/either power Control Wiring

sources
•Starts & Stops Genset
•Transfers Load from ATS
One Source to the
Other

Power to the
Load
Normal Conditions
•Generator is in
Utility Source the Automatic
Mode ready to
In ‘Normal’ start on
Condition command. The
engine is being
•Load is fed kept warm by a
through the ATS ATS-Generator block heater and
Control Wiring
from the Utility the starting
source battery is being
•ATS Continually kept refreshed by
Monitors the a battery charger.
ATS
Presence of Utility
Power

Load is Powered
by Utility
Power Failure

Utility Source X •ATS controller

senses
availability of
When Utility Fails
generator
•Mains sensing source and
relay senses times out TDNE
failure ATS-Generator
Control Wiring •ATS Contactor
•Time delay TDES transfers from
times out Normal position
to Emergency
•ATS sends start
position
signal to generator ATS
controller •The load is now
powered by the
•Generator starts
generator
and comes up to No Power to the
speed, providing Load
voltage to ATS.
Power Failure

Utility Source X •ATS controller

senses
availability of
When Utility Fails
generator
•Mains sensing source and
relay senses times out TDNE
failure ATS-Generator
Control Wiring •ATS Contactor
•Mains sensing transfers from
relay sends start Normal position
signal to generator to Emergency
CB12 position
ATS
•Generator starts •The load is now
and comes up to powered by the
speed, providing generator
No Power to the
voltage to ATS. Load
Power Failure

Utility Source X •ATS controller

senses
availability of
When Utility Fails
generator
•Mains sensing source and
relay senses times out TDNE
failure ATS-Generator
Control Wiring •ATS Contactor
•Mains sensing transfers from
relay sends start Normal position
signal to generator to Emergency
CB12 position
ATS
•Generator starts •The load is now
and comes up to powered by the
speed, providing generator
No Power to the
voltage to ATS. Load
Power Failure

Utility Source X •ATS controller

senses
availability of
When Utility Fails
generator
•Mains sensing source ATS
relay senses Contactor
failure ATS-Generator transfers from
Control Wiring
Normal position
•Mains sensing
to Emergency
relay sends start
position
signal to generator
CB12 •The load is now
ATS
powered by the
•Generator starts
generator
and comes up to
speed, providing
No Power to the
voltage to ATS. Load
Power Failure

Utility Source X •ATS controller

senses
availability of
When Utility Fails
generator
•Mains sensing source
relay senses
•ATS Contactor
failure ATS-Generator
Control Wiring transfers from
•Mains sensing Normal position
relay sends start to Emergency
signal to generator position
CB12
ATS •The load is now
•Generator starts powered by the
and comes up to generator
speed, providing
Load is Powered
voltage to ATS. by Generator
 Return to Normal

Utility Source

When Utility
Returns
•Mains sensing
relay senses ATS-Generator
availability of utility Control Wiring

•Time delay TDEN

times out
•ATS Contactor
transfers from ATS
Emergency position
to Normal position
causing a
momentary blink in Load is Powered
power to the load. by Generator
 Return to Normal

Utility Source

When Utility
Returns CB12 monitors
•Mains sensing relay & confirms utility
senses availability of is present for 1
ATS-Generator
utility Control Wiring minute then tells
the ATS to
•ATS Contactor
transfers from
connect the load
Emergency position to the utility
to Normal position ATS
causing a
momentary blink in
power to the load.
Load is Powered
by Generator
 Return to Normal
•The load is now
powered by the
Utility Source
utility

When Utility •Time delay TDES

times out
Returns
• ATS sends
•Mains sensing relay
shutdown signal to
senses availability of ATS-Generator generator controller.
utility Control Wiring
Engine stays
•ATS Contactor running in cooldown
transfers from mode
Emergency
•Time delay TDEC
position to Normal ATS times out
position causing a
momentary blink in •The engine stops
power to the load. and the generator
Load is Powered is ready for the
by Utility next outage
 Return to Normal

Utility Source •The load is now

powered by the
utility
When Utility
Returns •Engine runs on
without load for 2
•Mains sensing relay
minutes to allow
senses availability of ATS-Generator cool down
utility Control Wiring
• ATS sends
•ATS Contactor
shutdown si
transfers from
Emergency position
to Normal position ATS
causing a
momentary blink in
power to the load.
Load is Powered
by Utility
 Return to Normal
•The load is now
powered by the
Utility Source
utility

When Utility •rThe engine stops

and the generator
Returns
is ready for the
•Mains sensing relay next outage
senses availability of ATS-Generator •unning in cooldown
utility Control Wiring
mode until time
•ATS Contactor delay TDEC times
transfers from out
Emergency position
•The engine stops
to Normal position ATS and the generator is
causing a
ready for the next
momentary blink in
outage
power to the load.
Load is Powered
by Utility
Generator Basics