Emergency power generators, they are rarely needed but certainly indispensable. Many emergency power generators are installed at stables. Some have been there for a while and in some cases are not self-starting. ABATO Motoren has been able to carry out a conversion to the customer's existing generator for one of its customers. The control has been replaced so that:
– The unit switches on automatically in the event of a power failure
– Automatically runs a trial every month (no load)
– The alarm dialer and/or telephone dialer is connected
– An easy rotary switch is fitted for no load or load testing
– And.. a two-color LED lamp has been installed: you can see at a glance whether everything is OK.

This project involved more than just installing a new control unit. In most cases this is sufficient to make the above possible. However, the customer also had the following wishes:
– load testing with the mains switched on
– return without interruption after power failure

This is where the so-called “net-parallel operation” comes into play. What is needed for this compared to a normal generator? In short, it means that both the speed of the engine and the voltage of the generator are actively controlled. To make this possible, an electronic speed controller is placed for the frequency control and an automatic voltage regulator (AVR) that regulates the generator voltage.

The electronic control
Previously, the customer's generator had a mechanically controlled fuel pump, this is a centrifugal control that you also encounter on steam engines. By turning harder, steel balls are thrown apart, so that a valve is slowly closed, which makes the motor run slower again.

Here the engine was converted to an electronically controlled fuel pump. To make this possible, the mechanical controller on the injection pump was replaced by an electromagnetic actuator. A speed controller circuit board has also been mounted and adjusted. Now the aggregate frequency can be controlled exactly equal to that of the grid. A voltage control card was also built in. The mains voltage often changes throughout the year and now the generator voltage can be regulated exactly the same.

The moment the mains voltage fails, the generator will automatically start up and take over the load. The control then switches back to mains voltage completely automatically and without interruption when it feels that it is back. Previously, the generator had to be started up and switched manually.

As a result of the conversion, there is no longer any question of human action, which means that this concern has been removed from the customer. Certainly in combination with good maintenance, automatic testing and the alarm lamp, there is a lot of operational reliability in combination with little attention to the device. After the conversion, various tests are carried out, such as recurring power failures during the after-running of the engine.  

The installed control also stores the tests so that it can always be checked and demonstrated that the generator has worked.

Alarm lamp
The green lamp lights up when the generator is OK and the red lamp flashes when something is wrong with the generator. Due to the monthly automatic test, there is therefore a check every month. The alarm lamp has been placed on the facade of the building at our customer, so that it is always visible. The customer is always free to choose where the alarm lamp can be placed. Do you want to have an alarm lamp installed? That is also possible.

Energy-efficient heating
A circulating cooling water heating system has been installed in our customer's generator. The cooling water heater with circulation pump ensures that the engine is preheated properly and evenly. The pump heats up the engine block everywhere and little energy is wasted. This heating is a lot more economical than the one without a built-in pump.

Maintenance, SCIOS and breakdown service
ABATO Motoren works with various certified mechanics, each with their own specialty. What our technicians have in common is that they can give advice on everything. At this current customer, the advice was given to insulate the exhaust. This exhaust is at eye level and gets very hot. In addition, it has been found that the battery terminals are not shielded, which is why it is recommended to place protective caps. This minimizes the chance of a short circuit. In summary, these are very important points that are important for the SCIOS Scope 4 inspection. The SCIOS Scope 4 certification is a legally required inspection, in which safety and environmental aspects are central.

Several mechanics at ABATO Motoren are qualified to perform these inspections at our customers. An appointment was immediately made to inspect the SCIOS Scope 4 set, this is a legal requirement and the environmental service generally inquires about this. As a result, our customer also immediately receives a report and inspection certificate with regard to the generator. If there is something wrong, you can use the 365/24/7 breakdown service of ABATO Motoren!