A diesel generator is a type of small power generating device, which refers to an electric machine that uses diesel as fuel and a diesel engine as the main engine to drive a generator to generate electricity. Usually, a complete unit consists of a diesel engine, a generator, a control box, a fuel tank, starting and control batteries, protection devices, an emergency cabinet and other components. It can be used for daily power generation and emergency power generation in various homes, offices, large and small businesses, etc.
SR Power diesel generators have many advantages:
1. High thermal efficiency. High thermal efficiency means low fuel consumption and is economical. Diesel engines in particular are heat engines with a high thermal efficiency of 46%.
2. Diesel engines are easy to move.
3. Quick and easy to start up and can run at full load once started.
4. Wide power range. The power of a single machine can range from 0 to tens of thousands of kilowatts.
Therefore, durability testing of diesel generators is particularly important. As a leader in the diesel generator field, SR Power attaches great importance to the quality and durability of diesel generators, which has earned it a good reputation and a stable customer base around the world, and it has become the Chinese factory of Hyundai Motors brand.
Benefits and objectives of full load testing of diesel generator sets:
1. Through full load test, fix the rated power of diesel generator set, know the actual situation of the unit at any time, let customers know the operation of the unit and use electricity safely.
2. Through full-load drive testing, various drive performance indexes are obtained, the actual reasons for drive performance degradation are identified, and a scientific basis is provided for whether to replace the drive, thus reducing maintenance costs.
3. Through full load testing, you can determine whether the expected objectives can be achieved after the review.
4. Through full load testing, long-term full load testing can effectively remove carbon deposits, extend the overhaul time of diesel generator sets, and save costs.
5. The diesel generator sets have undergone full load testing, which provides a basis for the abandonment time of the units, thus enabling the customers to make reasonable arrangements for the use of the units.
First, according to the maximum load power of the diesel generator, select the corresponding N sets of load, and use cables to connect the generator, control output cabinet and load. First start the generator set, and according to the data displayed on the control screen, the load should be gradually made 25%, 50%, 75%, 100% of the total load, according to the water temperature, voltage, current, and other data are recorded at each stage (usually there is a load test table for diesel generator sets), to check whether the diesel generator set is working normally at each stage, whether the output current is stable, whether the output control cabinet has various segmentation functions, etc. The specific test time can be determined according to the actual running time of the generator set.
For SR Power, we adopt the most simple, direct and effective method: running diesel generators continuously at 90% of output without human supervision day and night. Running shelf life tests can expose more realistically . There are some issues with diesel engine reliability and durability in long-term use .
Under certain conditions, our diesel generators can run continuously for more than 2,000 hours, which is an excellent performance leading China. While other manufacturers compete on price, we focus on quality and durability, aiming to provide customers with the best product experience.
Before the durability test, some knowledge points also need to be clearly understood.
What is load capacity?
Load tolerance is a test specified in ISO 8528-12 and is the maximum load that can be applied to a diesel generator before the speed drops by more than 10%. For diesel generators with 50 Hz synchronous generators, this is usually the point at which the low speed protection also trips (usually for the motor and alternator) as the alternator will have difficulty producing voltage beyond this drop in rpm.
Load acceptance for diesel generators.
A typical load tolerance for diesel generators is 50-80%. For very small or very large devices, conditions above or below this value may occur.
Please note that engine manufacturers indicate the load acceptance percentage at a given point when the engine is warmed up. The performance of a cold engine will be worse than the data provided. Therefore, the engine must be equipped with a heater and/or glow plugs to aid starting and load acceptance. Another solution is to run the engine for a few minutes to warm up the oil and the cylinder block before accepting the first charging step.
Why is this important?
Load allowance is important because end users may not be aware that in most cases 100% load allowance is not realistic. For example, if a user purchases a 1000kVa machine with 800kWE, they can only claim 70% of the 800kWE, so they get 560kWe in one step instead of the full 800kWE.
Are you willing to accept higher fees?
It is generally not possible to obtain better load acceptance from a particular motor, as manufacturers optimize their units for best acceptance given other limitations in the motor design. Warming the engine with a heater or running the engine will ensure that the rated load acceptance of the engine is achieved during testing.
What if the customer wants a higher load capacity? The instructions say it is 100% required!
It is best to discuss this with your client before signing the contract. If you want to accept a larger load, you will need a larger motor. For example, a customer wants to buy a 100 kVA generator, but requires that it accept 100% of the load. A normal engine (after alternator efficiency conversion) that you use to supply 80 kWe has a load capacity of 75%, so it cannot handle 100% of the customer’s load.
The next engine size delivers 112 kWe (after alternator efficiency conversion), also at 75% load tolerance, thus delivering 84kWe in one step, meeting the customer’s requirements.
Diesel generators also require maintenance to operate at their optimum.
1. Test and maintain the unit’s starting battery.
If the battery is not maintained for a long time, if the water in the electrolyte cannot be added in a timely manner after evaporation, if there is no start-up charger, or if the charger used is not charged in a timely manner, the battery power battery will not meet the requirements. , It will inevitably affect the normal operation of the unit. To solve this problem, in addition to the configuration of a high-quality charger, necessary inspection and maintenance are required.
2. Prevent water from entering
Temperature changes cause water vapor in the air to condense, resulting in water droplets on the inner walls of the fuel tank and entering the diesel fuel, causing the diesel fuel to have an excessively high water content. If this type of diesel gets into the engine’s high-pressure oil pump, it will cause the precision coupling parts and plungers to rust, causing serious damage to the unit. Regular maintenance is effective in preventing breakdowns.
3. Change your engine oil regularly
Engine oil has a lubricating role, and engine oil also has a lifespan. It can usually be stored for two years. If stored for a long period of time, the performance of engine oil will change. Engine oil is prone to damage the parts of the unit, so it needs to be changed regularly.
4. Change the three filters regularly
The filter plays an important role in the unit, since it can filter diesel, oil and water. If dirt and impurities in the oil are precipitated on the filter grid for a long time, the filtering effect will decrease. If there are a lot of impurities precipitated, the oil circuit will be blocked, and the fuel supply will not be possible under normal load, and the unit will not work. With shock. Therefore, the generator manufacturer recommends replacing the filter to ensure the normal operation of the unit.
5. Regularly maintain the cooling and lubrication systems.
If the water pump, water tank and water supply pipes have not been cleaned for a long time, the water circulation will be poor and the cooling effect will be reduced. If the cooling system fails, the water temperature in the unit will become too high and the unit cannot be shut down. If the water tank leaks, the water level in the tank will drop and the machine will stop.
6. Check fuel and gas distribution systems regularly.
The main output of the engine is the combustion of fuel in the cylinder. The fuel is sprayed from the nozzle, and after combustion, carbon will be deposited in the nozzle. When the amount of deposit increases, it will affect the fuel injection amount of the fuel injector to a certain extent, and the start time of the ignition advance of the fuel injector will be inaccurate. The amount of fuel injected into each cylinder of the engine will be uneven, resulting in unstable working conditions. Therefore, the fuel system needs to be cleaned and replaced regularly, and the gas distribution system needs to be adjusted to ensure uniform ignition.
After much research and testing, we’ve compiled eight tips to help extend your battery life.
1. Pay attention to the oil pressure During the operation of a diesel engine, the oil pump transmits the lubricating oil pressure to the friction surfaces of each part, and an oil film is formed to prevent the rubbing parts from contacting each other. Direct contact reduces wear. Always pay attention to the oil pressure during use. If the oil pressure is too low, immediately stop the vehicle for inspection and maintenance. If the oil pressure is too high, the oil film will be destroyed and wear will increase. And removed in time.
2. Pay attention to temperature changes. The temperature of a diesel engine is mainly reflected in the coolant temperature and lubricating oil temperature. During the operation of a forced circulation diesel engine, the water temperature should be kept at 70-90 ℃, and the engine oil temperature should be kept at 70-80 ℃. If it is too high, it will damage the cylinder gasket, piston and piston ring, and the viscosity of the engine oil will decrease, resulting in poor lubrication performance. If it is too low, it will increase fuel consumption and smoke generation. Therefore, you should always pay attention to the coolant temperature during work and eliminate abnormalities in time.
3. Pay attention to maintenance during the break-in period. A new or refurbished diesel engine must be run-in during the break-in period. The surfaces of diesel engine parts move in conjunction with each other, so they have a certain degree of precision and smoothness, but they are uneven in appearance and have small mounting clearances. The purpose of the break-in is to make the mating moving surfaces smoother and provide more appropriate clearances to prevent premature wear. The break-in period is operated without load for 50 hours, during which the speed is changed from low to high and the load from small to large. Overspeed or overload operation is not permitted. After the break-in period is over, it is necessary to change the engine oil in the crankcase, clean the crankcase and each lubricating oil circuit, and clean or replace the oil filter element.
4. Strengthening maintenance is the key to extending the life of diesel engines. Daily maintenance, regular maintenance and frequent inspections should be carried out, focusing on ensuring that the cooling water and engine oil are sufficient, that the technical condition of each part of the diesel engine is good, and that there are no malfunctions. Be eliminated in time. The “three filters” must be clean and smooth. When working in a dusty environment at the site, the air filter should be cleaned once a day. Other maintenance work should also be carried out in accordance with the prescribed procedures.
5. Do not accelerate suddenly when the diesel engine is hot. This will cause violent vibrations and increase friction on the contact surfaces. If you press the accelerator hard when the engine is cold, the viscosity of the lubricating oil will increase and it will be difficult to flow, which will increase the wear of the mechanical parts. In severe cases, it may even cause serious accidents such as cylinder failure, starting, burning tiles, and axle lock. Therefore, always refuel when the car is cold or hot, at high, medium and low speeds, and do not keep pressing the accelerator.
6. Change gears correctly while driving To prevent the diesel engine from running at high speed for a long time and causing wear, you need to change gears at the right time according to the road conditions and high and low speeds. Avoid gear manipulation. Even if you are driving uphill or on a lava road, select the appropriate gear and do not run the engine at high speed when the load is insufficient.
7. It is strictly prohibited to start and operate a diesel engine at low temperatures where the water temperature is over 70°C, as this will cause wear to worsen. Wear will be greater during low temperature start-up. If you start and preheat the engine once at 2°C, the wear is equivalent to driving 50km. Therefore, the heating water must be preheated when starting in winter. It is best to leave it indoors overnight. Do not operate the engine at low temperatures for a long time after starting.
8. Select the correct fuel The characteristics of diesel fuel are mainly determined by the cetane number and impurities. If you choose the wrong one, it will be easy to be damaged during operation and may cause severe wear on the collision surface of mechanical parts. When using, please select the corresponding diesel type according to the compression ratio of the diesel engine and the season to reduce the wear and corrosion of mechanical parts.