- A generator set is the combination of and engine to create power and an alternator to change that power into electricity.
- The engine turns a shaft that in turn is connected to the alternator. This turning of the alternator creates the electrical power.
- As there are different types of power all over the world, different generator sets are built to create different forms of electrical power.
- In Indonesia the power is 230v at 50Hz the same as is supplied from your sockets at home. In the United States of America this power is usually 110v at 60Hz.
- Where ever in the world the generator set is built for, the following diagram shows the general parts and construction of the system.
WHAT IS A GENERATOR CONTROLLER?
- A generator controller is a device used to monitor, start and stop a generator.
- Just like any other engine, your car for example, a generator set has a number of things that must be monitored and checked during normal operation.
- Some of the items that are monitored are oil pressure, engine temperature, fuel level among others.
- Also just like when you are starting your car you need to control the start and fuel inputs to the engine. These are controlled with automatic switches called relays.
- Unlike your car, a generator must also check the output of the alternator. This will be in voltage, current and frequency. These connections allow the controller to monitor the output to ensure the generator is operating correctly and is not overloaded.
- The reason for all this checking is that normally a generator will be in a separate building but unlike your car, no one will be available to check these settings. In your car you would be there when driving to switch off the engine if there was a problem.
- The below diagram shows different parts of an engine and generator with the monitor and main control links to the DSE module.
WHAT IS A MANUAL START UNIT?
- A manual start unit is the simplest form of electronic generator controller and is one step above a ‘pull start’ generator.
- This device is almost identical to the controls in your car. The device usually has a key and button to start the generator.
- If your mains power fails and you need to use generator power, you have to turn the key, to start the generator manually.
- The 701 and 501 are modules of this type. They only have basic controls to monitor items such as oil pressure and engine temperature.
- The manual start unit is ideal for stand alone functions and portable generator sets as these would normally have personnel to start and stop the generator. Examples of this are the generators often seen at roadworks.
- An automatic start module has all the same features as a manual start
- The unit is capable of receiving a start signal from an external source. This could be a start switch located inside the factory where the generator is sited for instance.
- The unit can also be set to start automatically when the mains power or some other input is given to the module.
- These types of module are often used with an automatic transfer switchdiscussed later.
- 3110, 4410, 6110, 7210, 7310 and 7510 are examples of this type of module. They still have only basic controls but have the advantage of being able to receive a start signal from an external source.
- An automatic transfer switch (ATS) is different to a generator controller as it only monitors the mains and generator power but does not start the engine.
- The unit normally sits in a monitor panel and has connections to the generator controller.
- When the mains power fails the ATS gives a command to the generator controller to start the generator set.
- Once the generator set is up and running the ATS then switches over the power from mains to generator.
- The ATS will then check the mains to see when the power returns.
- Once the power returns the ATS will switch over to the mains and then tell the generator to stop.
- 705 and 4130 modules are ATS units.
- An automatic mains failure (AMF) module combines the automatic start module with an automatic transfer switch.
- The module will monitor the mains and generator power like an ATS but added to this is the ability for the module to control the generator as well.
- The module works like an auto start module in operation. The difference being it can create its own start input from conditions it can monitor.
- The AMF module is normally used when a backup power system is required for a site.
- Our own factory has an AMF panel for backup power if the mains power fails.
- The 4120, 6120, 7220, 7320 and 7520 are examples of AMF systems.
- A synchronising and load share unit is the ultimate generator controller.
- They come in many forms including allowing up to 16 generators to be combined together and even providing power to the national grid electricity system.
- The synchronising and load sharing module can also be used in conjunction with a ‘mains controller’ to monitor the mains and act as an ATS for all the generator sets.
- 5510 and 7510 are modules capable of providing multiple generator set systems.
- 5520 and 7520 are single set controllers to allow one generator to act as mains backup and synchronise with the mains supply.
- 5560 and 7560 are mains controller and ATS modules.
- DSE’s own onsite backup power system uses synchronising and load sharing to allow three generator sets to start up automatically (upon mains failure) or manually (before mains failure) to power the factory. These generators then all connect together on a common wiring. This is then connected ‘en block’ to the factory, supplying our power when there is a power cut. The advantage of this system is that when the power required by the factory is reduced, then the system can stop one or more of the three generators, thereby saving fuel. If the power then rises again it can start the generator again and connect it to the other two.
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