The Best Things About Components Of A Generator

The main components of a generator can be classified as follows. 

1. Engine
2. Alternator
3. Fuel system
4. Voltage regulators
5. Cooling and exhaust system
6. Lubrication system
7. Battery charger
8. Control panel
9. Main assembly 

1:Engine

The engine is the source of the input mechanical energy to the generator. The size of the engine is directly proportional to the maximum power output the generator can supply. There are several factors that you should need to keep in mind while assessing the engine of your generator.Generator engines operate on a variety of fuels such as diesel, gasoline, propane (in liquefied or gaseous form), or natural gas. Smaller engines usually operate on gasoline while larger engines run on diesel, liquid propane, propane gas, or natural gas. Positive engines can also operate on a dual feed of both diesel and gas in a bi-fuel operation mode.
For further insights, explore and delve into this valuable post.

2:Alternator

Rotor / Armature: This is the moving part that produces a rotating magnetic field in any of the following ways:

• By induction: These are known as brushless alternators & are usually used in large generators.
• By permanent magnets: This is common in small alternator units.

An exciter is a small source of direct current (DC) that energizes the rotor through an assembly of conducting slip rings &brushes.The rotor generates a moving magnetic field around the stator, which induces a voltage difference between the windings of the stator. This produces the alternating current (AC) output of the generator.The following are the factors that you need to keep in mind while assessing the alternator of a generator.

• Metal versus Plastic Housing: An all-metal design ensures durability of the alternator. Plastic housings get deformed with time & cause the moving parts of the alternator to be exposed. This increases wear & tear & more importantly, is hazardous to the user.
• The alternator: is the part of the generator that produces the electrical output from the mechanical input supplied by the engine. It contains an assembly of stationary & moving parts encased in housing. The parts work together to cause relative movement between the magnetic & electric fields, which in turn generates electricity.
• Stator: This is the stationary part. It contains a set of electrical conductors wound in coils over an iron core. 
• Brushless Design: An alternator that does not use brushes requires less maintenance & also produces cleaner power.

Ball Bearings versus Needle Bearing: Ball bearings are preferred & last longer.

3:Fuel System

The fuel tank usually has sufficient capacity to keep the generator operational for 6 to 8 hours on an average. In the case of tiny generator units, the fuel tank is a part of the generator skid base or is mounted on top of the generator frame. 

• Pipe connection from fuel tank to enginethe supply line directs fuel from the tank to the engine & the return line directs fuel from the engine to the tank.
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• Ventilation pipe for fuel tank the fuel tank has a ventilation pipe to prevent the build-up of pressure or vacuum in the work of refilling & drainage of the tank. When you refill the fuel tank, be positive metal-to-metal contact between the filler nozzle & the fuel tank to keep away from sparks.
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• Fuel pump: This transfers fuel from the main storage tank to the day tank. The fuel pump is usually electrically operated.
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• Overflow connection from fuel tank to the drain pipe: This is necessary so that any overflow in the work of refilling of the tank does not cause spillage of the liquid on the generator set.
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• Fuel Water Separator / Fuel Filter: This separates water & foreign matter from the liquid fuel to protect other parts of the generator from corrosion & contamination.
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• Fuel Injector: This atomizes the liquid fuel & sprays the necessary amount of fuel in to the combustion chamber of the engine.

4:Voltage Regulator

Exciter Windings: Conversion of DC Current to AC Current. The exciter windings now function similar to the primary stator windings & generate a little AC current. The exciter windings are connected to units known as rotating rectifiers.

• As the name implies, this part regulates the output voltage of the generator. The mechanism is described below against each part that plays an element in the cyclical technique of voltage regulation.
• Voltage Regulator: Conversion of AC Voltage to DC Current. The voltage regulator takes up a little portion of the generator’s output of AC voltage & converts it in to DC current. The voltage regulator then feeds this DC current to a set of secondary windings in the stator, known as exciter windings.
• Rotor / Armature: Conversion of DC Current to AC Voltage. The rotor / armature now induces a bigger AC voltage across the windings of the stator, which the generator now produces as a bigger output AC voltage.
• Rotating Rectifiers: These rectify the AC current generated by the exciter windings convert it to DC current. This DC current is fed to the rotor / armature to generate an electromagnetic field in addition to the rotating magnetic field of the rotor / armature.

5:Cooling & Exhaust Systems/Cooling Process

Continuous usage of the generator causes its various parts to get heated up. It is essential to have a cooling and ventilation process to withdraw heat produced in the method.Raw/fresh water is sometimes used as a coolant for generators, but these are mostly limited to specific situations like small generators in city applications or large units over 2250 kW and above. Hydrogen is sometimes used as a coolant for the stator windings of large generator units since it is more efficient at absorbing heat than other coolants. Hydrogen removes heat from the generator and transfers it through a heat exchanger in to a secondary cooling circuit that contains de-mineralized water as a coolant. 

This is why large generators and small power plants often have large cooling towers next to them. For all other common applications, both residential and industrial, a standard radiator and fan is mounted on the generator and works as the primary cooling process.It is essential to check the coolant levels of the generator oneveryday basis. The cooling process and raw water pump ought to be flushed after every 600 hours and the heat exchanger ought to be cleaned after every two, 400 hours of generator operation. The generator ought to be placed in an open and ventilated area that has adequate supply of fresh air.

Exhaust Process

Exhaust fumes emitted by a generator are like exhaust from any other diesel or gasoline engine and contain highly poisonous chemicals that require to be properly managed. Hence, it is essential to put in an adequate exhaust process to dispose of the exhaust gases. This point cannot be emphasized as carbon monoxide poisoning remains of the most common causes for death in post hurricane affected areas because people tend to not even give it some thought until it’s late.

6:Lubricating System

Since the generator comprises moving parts in its engine; it requires lubrication to be positive durability & smooth operations for a long timeframe. The generator’s engine is oiled by oil stored in a pump. You ought to check the level of oiling oil every 8 hours of generator operation. You ought to also check for any leakages of oil & modify the oiling oil every 500 hours of generator operation.

7:Battery Charger

The start function of a generator is battery-operated. The battery charger keeps the generator battery charged by supplying it with an exact float voltage. If the float voltage is low, the battery will stay undercharged. If the float voltage is high, it will shorten the life of the battery. Battery chargers are usually made of stainless steel to prevent corrosion. They are also fully automatic & do not require any adjustments to be made or any settings to be changed. The DC output voltage of the battery charger is set at two.33 Volts per cell, which is the exact float voltage for lead acid batteries. The battery charger has an isolated DC voltage output that does interfere with the normal functioning of the generator.

8:Control Panel

This is the user interface of the generator & contains provisions for electrical outlets & controls. 

• Electric start & shut-down Auto start control panels automatically start your generator in the work of a power outage; monitor the generator while in operation, & automatically shut down the unit when no longer necessary.
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• Engine gauges Different gauges indicate important parameters such as oil pressure, temperature of coolant, battery voltage, engine rotation speed, & period of operation. Constant measurement & monitoring of these parameters allows built-in shutdown of the generator when any of these cross their respective threshold levels.
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• Other controls Phase selector switch, frequency switch, & engine control switch (manual mode, auto mode) among others.
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• Generator gauges, and the control panel also has meters for the measurement of output current & voltage, & operating frequency. To learn more about control panels or related issues, study this post: 'Generator Scanning And Diagnostic.

9:Main Assembly / Frame

All generators, portable or stationary, have customized housings that provide a structural base support. The frame also allows for the generated to be earthed for safety.