Many UK businesses right across the country have taken the smart step of investing in a standby generator. Having a source of backup power is a crucial step in preventing your business operations from coming to a standstill should your local area be subjected to a blackout.
Standby generators and generator power solutions have seen a rise in popularity in recent years, and it is not difficult to see why. Once you’ve decided how to choose the best diesel generator for your needs, you’ll need to think about how best to service it, and how to troubleshoot.
Whilst diesel generators are generally extremely durable and dependable, there are inevitably certain issues and problems you’ll want to keep an eye out for. Here at Vital Power our team of expert engineers can help with any repairs, and can provide advice on how to keep your generator in top working condition.
Read more about some of the most common diesel generator issues…
Of course, you invest in a diesel generator so you have a reliable source of power when there’s an outage. However, to make sure this is always the case and on hand when you need it, you’ll need to maintain your generator’s battery.
Because the generator can stand idle for prolonged periods of time, the battery can often drain unless placed on a trickle charger. However, keeping your battery ready to go is an easy, quick fix that you can add to your maintenance routine.
Studies have shown that in order to keep your generator in perfect working order, batteries should be replaced every three years. Another way in which to prolong their life is to get them serviced on a regular basis.
A diesel generator being out of fuel is one of the most common problems owners run into. For this reason, make sure the generator fuel level is the first thing you check if your generator won’t start.
For the most part, fuel leaks relate to human error or a fuel level gauge error. Sometimes, the level gauges may not be working properly and may get stuck in position, showing that there is still plenty of fuel when in fact it is almost empty.
To avoid diesel fuel shortages, Vital Power offers regular refuelling and maintenance services for businesses.
Within all modern, state-of-the-art diesel generators there will be a built-in air-filtration system, designed to make sure the carburettor receives the right level of oxygen to mix with the fuel. One of the most important elements of the internal combustion engine is the filtration system. This is a series of pipes which is designed to allow sufficient air to reach the engine.
Depending on the area that you have installed your unit, it is possible that debris and dirt can infiltrate these pipes. In some instances, this can lead to the mechanisms being shattered by rocks moving at extremely fast speeds.
To avoid clogs or damage from debris, make sure you or a specialist like one of the Vital Power team regularly cleans out the generator filtration system. Conducting a manual inspection of this on a consistent basis can help you to prevent any lasting damage.
As mentioned above, the commercial power systems that are being operated frequently are typically forced to take on heavy workloads. To ensure a maintainable level, make sure you conduct load bank testing for your generator system.
Though they’re extremely reliable, generators can suffer from oil, fuel, or coolant leaks. If you do find a leak the best thing to do is call a qualified technician to come and patch or replace the necessary components.
However, your generator can sometimes think there is a leak when in fact there isn’t one. You will hear this referred to as ‘wet stacking’; it is the accumulation of unburned fuel, condensed water, carbon particles and acids in the exhaust system.
Regular scheduled services and manual generator checks can help make sure any leaks are picked up on before they cause major damage and lead to more expensive repairs.
Every generator has a control panel that allows you to manage the generator settings. This panel also displays important engine and alternator information. Sometimes, your generator won’t start simply because its auto controls have been left in the ‘off’ position after a routine test or inspection.
According to our engineers, the majority of the service calls for control panel problems are caused by operators failing to turn on the automatic controls. So, if you can’t turn your generator on, make sure to check the auto controls first!
Generators put in a lot of work, even when they’re sitting seemingly idle. The role of a block heater is to heat the coolant so that it circulates the engine block, it needs to keep the engine block warm to prevent thickening of oil. Eventually, all block heaters will fail because they run all day, every day – so this is something you should be aware of.
Contrary to misconceptions, block heaters are essential, even in warm climates. In general, they reduce wear and tear by maintaining more consistent temperatures throughout the cooling system.
Keep an eye on your generator block heater, and replace it when needed to avoid generator failure.
To have our expert team’s advice and assistance with repairs, contact Vital Power today.
Generators need to run smoothly and efficiently to effectively power necessary equipment in industrial settings. However, there are a few common problems industrial generators encounter that factory managers, OEMs and owners should be aware of in order to prevent downtime.
The single most common generator problem is neglected maintenance. Think of the engine on an industrial generator the same as you would the engine in your car. It is well known that there are going to be problems if you don’t check the engine’s components for wear and tear in addition to preventative maintenance.
Proper engine maintenance is key to running your generator efficiently. Having a maintenance plan that coincides with the manufacturer and distributor’s recommendations will often comprise of routine, semi-annual and annual generator services. Often, this entails inspections and service to your:
Part of a proper maintenance plan is an annual load bank test. It will eliminate wet stacking in diesel generators by burning off un-burnt fuel, oil and carbon in the cylinders and exhaust system. It also will exercise and test the unit’s fuel and cooling systems and evaporate moisture from inside the generator and engine.
A common mistake is improper sizing of an industrial generator. Businesses often want to buy a larger generator than what is needed for their application as a way to scale for future needs. Unfortunately, running a generator with too light of a load can result in serious damage and wasteful inefficiencies. Whenever the generator is running, you have to utilize at least 35% of the load capabilities. Engine distributors commonly run into issues where a client says they will add additional equipment in the near future. Unfortunately, if it doesn’t happen fast enough, the generator they just purchased will run inefficiently and may see damage.
A prominent issue that results from improper loading is wet stacking. This commonly occurs when a generator doesn’t operate with a large enough load. As a result, the engine’s operating temperature doesn’t get hot enough for the expansion joints in the exhaust system to seal up properly. Running too light of a load doesn’t entirely burn the diesel fuel completely, allowing wet fuel to pool in the engine stack. Together, these issues allow wet fuel to leak through the exhaust, which can lead to major problems such as destructive fires.
Often, operators do not supply enough fuel when in operation. The obvious effect resulting from a lack of fuel is the generator shutting down because there is nothing to burn for power, but another, less thought of effect is the intake of air into the fuel system. Additionally, not running your generator on a regular basis can cause air in the fuel system. This can shut down a diesel generator due to tighter tolerances on Tier 4 fuel systems.
Businesses that don’t implement a regular maintenance plan combined with a lack of regular usage tend to have stagnant fuel in the tank. Stagnant fuel results in water condensation, which in turn, causes an acceleration of microbiological growth. This creates contamination and damaging sludge to appear, which can hurt fuel filters, create clogs and cause leaks.
The easy solution to most generator problems is found in regular maintenance. Generator owners should have a planned service agreement with a company they trust. A planned service agreement is the key solution for mitigating and preventing problems associated with generators in industrial settings. Furthermore, working with the generator manufacturer and distributor will outline proper usage to ensure the correct load amounts are used regularly.
Trust the generator experts and work closely with them to ensure your generator runs when it’s needed, how it’s needed. To learn more about avoiding common generator problems, check out our guide to running your generator efficiently. You’ll learn how to keep fuel consumption and operating costs down, while maximizing the longevity of your gen set. Download the guide today.