How Do Diesel Generators Work? - Jubilee Energy

A diesel generator is a machine that converts mechanical energy into electrical energy using diesel as fuel. In other words, it makes electricity when there’s no power supply.

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These generators are widely used in homes, businesses, and industrial sites as a reliable backup or in areas without access to the power grid.

They’re incredibly helpful – but how do they actually work? Let’s break it down so you can understand how they work and when to use them.

The Basics of Diesel Generators

A diesel generator has three main components — the engine, the alternator, and the control system. Each plays a critical role in ensuring the generator produces electricity efficiently and safely. 

In summary – the engine generates motion, the alternator converts motion into electricity, and control system manages output. Let’s briefly explore each one:

The Engine: The Power Source

At the heart of every diesel generator is the engine. The engine is like a pump that uses diesel fuel to create motion, which powers the generator.

The engine burns diesel fuel to produce mechanical energy. Diesel engines are internal combustion engines, meaning they rely on a controlled explosion of fuel and air to generate motion. 

The engine draws in air, which mixes with diesel fuel. This air-fuel mixture is compressed to high pressure in the engine’s cylinders. Diesel engines are known for their high compression ratios, which make them more fuel-efficient than petrol engines. 

The high pressure generates enough heat to ignite the diesel fuel (no spark plug needed). This combustion releases energy, moving the engine’s pistons. The pistons’ motion is what drives the generator’s alternator, converting the mechanical energy into electricity.

The Alternator: Turning Motion Into Electricity

The alternator is like a bicycle dynamo that powers a light as you pedal. It converts the motion from the engine into electrical power.

The alternator is where mechanical energy is transformed into electrical power. This component operates on the principles of electromagnetic induction. Inside the alternator, a rotor spins within a stator, which contains coils of wire. 

As the rotor turns, it creates a magnetic field that induces an electrical current in the stator. This process produces alternating current (AC) electricity, which is then routed to power electrical systems. Some generators include a rectifier to convert AC to direct current (DC) if needed for specific applications.

The Control System: Managing Power Output

The control system acts as the generator’s brain. It keeps everything running smoothly, adjusts power when needed, and shuts things down if something goes wrong.

It does this by regulating power output, monitoring system performance, and protecting the generator from damage. 

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Key functions of the control system include voltage regulation to ensure a steady power supply to connected devices, safety features that shut down the generator in case of issues like overheating or low oil pressure, and monitoring capabilities that display key information like fuel levels, power output, and engine status. 

Modern diesel generators often include advanced digital control panels, allowing users to easily adjust settings and monitor performance.

The Fuel System: Ensuring Continuous Operation

Diesel generators rely on a dedicated fuel system to supply diesel to the engine. This system includes a fuel tank to store diesel, pumps and filters to deliver clean fuel to the engine, and injectors to spray the fuel into the engine cylinders for combustion. 

Diesel is favoured for generators because it’s energy-dense, efficient, and widely available. This makes diesel generators suitable for long-term operation in demanding environments.

Cooling and Exhaust: Managing Heat and Emissions

Diesel engines generate a significant amount of heat and emissions during operation. To ensure safe and efficient performance, diesel generators include systems for cooling and exhaust. 

A cooling system—either liquid-cooled or air-cooled—prevents the engine from overheating. The exhaust system directs harmful gases away from the generator and reduces noise with a muffler. 

Proper maintenance of these systems is essential for keeping the generator running smoothly.

Starting the Generator: Battery and Ignition

Most diesel generators use a small battery-powered motor to start the engine. This motor provides the initial spark of motion needed to get the engine running. Once the engine is running, it takes over, and the generator begins producing electricity.

When Are Diesel Generators Used?

Diesel generators are versatile and can be tailored to a variety of needs. Common uses include: 

• Backup power for homes and businesses if there are any outages
• Providing power in remote areas or supplementing unreliable grid electricity
• Supplying electricity for tools and equipment in off-grid construction locations
• Powering lighting, sound, and other equipment for outdoor or temporary events.

Why Diesel Generators Are a Reliable Choice?

Diesel generators have a well-earned reputation for durability, fuel efficiency, and long operational life. They’re capable of delivering power consistently over extended periods, making them ideal for critical applications. Their robust design also means they can withstand harsh conditions, whether they’re powering a construction site or supporting emergency services.

Selecting the correct electrical configuration is essential when choosing a generator for your environment. This includes determining the appropriate phase, voltage, kilowatts (kW), and hertz for your specific application. A generator set (genset) consists of two primary components: an industrial engine and a generator end. The engine produces horsepower and RPM, which the generator end converts into electricity.

Phases in Industrial Generators

Single-Phase Generators

• Used for smaller single-phase loads.
• Common in residential environments.
• Typically do not exceed 40 kW.
• Power factor: 1.0.

Three-Phase Generators

• Designed for larger industrial power needs.
• Can support both single-phase and three-phase loads.
• Suitable for running high-horsepower industrial motors and distributing power across multiple lines.
• Power factor: 0.8.

Adjusting Power Output with Phases

Increasing Power Output Rating

• Converting single-phase to three-phase can increase kW output by 20–30%.
• Requires a reconnectable generator end and proper load balancing.

De-Rating (Three-Phase to Single-Phase)

• Reduces kW output by approximately 30%.
• Example: A 100 kW three-phase generator will de-rate to about 70 kW in single-phase.

Key Considerations for De-Rating

• Calculate adjusted power from kVA rather than kW using this formula:
  Adjusted Power = (2/3) × kVA
  Example: A 150 kVA single-phase generator de-rates to 100 kVA.
• The generator end must typically have 10 or 12 reconnectable leads.
• Ensure individual line amps do not exceed the rated capacity when using single-phase loads.

Voltage Options for Commercial Generators

Single-Phase Voltages

• 120
• 240
• 120/240

Three-Phase Voltages

• 208
• 120/208
• 240
• 480 (most common for industrial gensets)
• 277/480
• 600 (common in Canada)
• Volt

Additional Voltage Options

• Includes uncommon voltages like 220, 440, , , and up to 13,500.

Determining the Required Voltage

Key Factors to Evaluate

• Incoming Voltage: Voltage from the mains transformer to the building.
• Maximum Amperage: Required to power your specific equipment.
• Startup Amperage: For industrial motors with high initial power demands.
• Utility Frequency:
  • 60 Hz: Common in the U.S. and parts of Asia.
  • 50 Hz: Standard in most other regions.
  • 400 Hz: Specialized for large ships and airplanes.

Consulting Professionals

• An electrician or electrical contractor can help assess your facility’s needs.
• Use tools like power calculators and amperage charts for additional accuracy.

Adjusting the Voltage of a Generator

Overview

Voltage adjustments involve reconfiguring leads on the generator end. Most three-phase generators have 10 or 12 leads that can be rearranged to achieve different voltage combinations.

Common Adjustments

• Examples include converting 208V to 480V or 480V to 240V.
• Achievable if the generator end is reconnectable.

Considerations

• Specialized high-voltage gensets (e.g., 13,500 Volt) are less practical for alterations.
• Some systems may require significant rewiring, and certain generator ends are not reconnectable.

Additional Component Adjustments

Gauges

• Older generators may require gauge replacements to reflect new output levels.
• Digital control panels on modern gensets can often be reprogrammed.

Circuit Breakers

• Updated to match new amperage requirements.
• Configurations can vary (e.g., single Amp breaker or two 600 Amp breakers).

Voltage Regulators

• Adjustments to sensing wires are critical to avoid damage.
• Modern regulators are integrated into control panels, simplifying changes but increasing costs.

Transformers

• May need rewiring to support the new voltage configuration.

Automatic Transfer Switch (ATS)

• Amperage adjustments ensure smooth transitions during utility outages.

Understanding and configuring phase and voltage options for industrial generators is a technical process that requires careful evaluation and expertise. For complex adjustments or questions about your specific environment, consult a professional technician or commercial electrician. Contact us at 800-853- or through our online form for assistance with sizing, configuring, or altering generator setups.

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