QUESTION TO BE ASKED ABOUT GENSET 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

21. 22. 23. What is the difference between kW and kVa? What is a power factor? What is the difference between standby, continuous, and prime power ratings? If I am interested in a generator that is not the voltage I need, can the voltage be changed? What does an Automatic Transfer Switch do? Can you convert a 60 Hz generator to 50 Hz? How do I determine what size Generator I need? What the advantages of buying a diesel generator instead of gas generator? Who are the major players (Cummins, Kirloskar, etc.) How is the market segmented, KVA wise and sector wise What are the installed capacities? How large a generator do I need for my home or small business? Single or Three Phase? Is a 3-phase generator suitable for the average homeowner or small business? What is the function of the electronic controller on a GenSet? Can I use a portable generator for an automatic starting system? What kind of generator should I purchase - gaseous or diesel? Do 3600 RPM diesel generators last as long as 1800 RPM GenSets? What does the term "Wet Stacking" mean in a diesel engine? What kind of maintenance will my diesel generator need How do transfer switches work? What is the difference between standby/emergency/maximum and prime/continuous duty applications? How are decibel levels calculated on generators? What is the difference between single and three phase?

ANSWERS What is the difference between kW and kVa? The primary difference between kW (kilowatt) and kVA (kilovolt-ampere) is the power factor. kW is the unit of real power and kVA is a unit of apparent power (or real power plus re-active power). The power factor, unless it is defined and known, is therefore an approximate value (typically 0.8), and the kVA value will always be higher than the value for kW. In relation to industrial and commercial generators, kW is most commonly used when referring to generators in the United States, and a few other countries that use 60 Hz, while the majority of the rest of the world typically uses kVa as the primary value when referencing generator sets. To expand on it a bit more, the kW rating is essentially the resulting power output a generator can supply based on the horsepower of an engine. kW is figured by the horsepower rating of the engine times .746. For example if you have a 500 horsepower engine it has a kW rating of 373. The kilovoltamperes (kVa) are the generator end capacity. Generator sets are usually shown with both ratings. To determine the kW and kVa ratio the formula below is used. 0.8 (pf) x 625 (kVa) = 500 kW What is a power factor? The power factor (pf) is typically defined as the ratio between kilowatts (kW) and kilovolt amps (kVa) that is drawn from an electrical load, as was discussed in the question above in more detail. It is determined by the generators connected load. The pf on the nameplate of a generator relates the kVa to the kW rating (see formula above). Generators with higher power factors more efficiently transfer energy to the connected load, while generators with a lower power factor are not as efficient and result in increased power costs. The standard power factor for a three phase generator is .8. What is the difference between standby, continuous, and prime power ratings? Standby power generators are most often used in emergency situations, such as during a power outage. It is ideal for applications that have another reliable continuous power source like utility power. Its recommend usage is most often only for the duration of a power outage and regular testing and maintenance. Prime power ratings can be defined as having an unlimited run time, or essentially a generator that will be used as a primary power source and not just for standby or backup power. A prime power rated generator can supply power in a situation where there is no utility source, as is often the case in industrial applications like mining or oil & gas operations located in remote areas where the grid is not accessible. Continuous power is similar to prime power but has a base load rating. It can supply power continuously to a constant load, but does not have the ability to handle overload conditions or work as well with variable loads. The main difference between a prime and continuous rating is that prime

power gensets are set to have maximum power available at a variable load for an unlimited number of hours, and they generally include a 10% or so overload capability for short durations.

If I am interested in a generator that is not the voltage I need, can the voltage be changed? Generator ends are designed to be either reconnectable or non-reconnectable. If a generator is listed as reconnectable the voltage can be changed, consequently if it is non-reconnectable the voltage is not changeable. 12-lead reconnectable generator ends can be changed between three and single phase voltages; however, keep in mind that a voltage change from three phase to single phase will decrease the power out put of the machine. 10 lead reconnectable can converted to three phase voltages but not single phase. For more information, heres a useful pdf file from the U.S. Army Corps of Engineers.

What does an Automatic Transfer Switch do? An automatic transfer switch (ATS) transfers power from a standard source, like utility, to emergency power, such as a generator, when the standard source fails. An ATS senses the power interruption on the line and in turn signals the engine panel to start. When the standard source is restored to normal power the ATS transfers power back to the standard source and shuts the generator down. Automatic Transfer Switches are often used in high availability environments such as data centers, manufacturing plans, telecommunication networks and so forth.

Can a generator I am looking at parallel with one I already own? Generator sets can be paralleled for either redundancy or capacity requirements. Paralleling generators allows you to electrically join them to combine their power output. Paralleling identical generators will not be problematic but some extensive thought should go into the overall design based on the primary purpose of your system. If you are trying to parallel unlike generators the design and installation can be more complex and you must keep in mind the affects of engine configuration, generator design, and regulator design, just to name a few. For more information and details on paralleling standby generators in critical systems take a look at this informative article.

Can you convert a 60 Hz generator to 50 Hz? In general, most commercial generators can be converted from 60 Hz to 50 Hz. The general rule of thumb is 60 Hz machines run at 1800 Rpm and 50 Hz generators run at 1500 Rpm. With most generators changing the frequency will only require turning down the rpms of the engine. In some cases, parts may have to be replaced or further modifications made. Larger machines or machines already set at low Rpm are different and should always be evaluated on a case by case basis. We prefer to have our experienced technicians look at each generator in detail in order to determine the feasibility and what all will be required. How do I determine what size Generator I need? Getting a generator that can handle all your power generation needs is one of the most critical aspects

of the purchasing decision. Whether you are interested in prime or standby power, if your new generator can't meet your specific requirements then it simply won't be doing anyone any good because it can put undue stress on the unit and even damage some of the devices connected to it. Determining exactly what size of generator to get is often very difficult and involves a number of factors and considerations. To get more detailed information on this subject, please visit our expanded article on Sizing a Generator. What the advantages of buying a diesel generator instead of gas generator? Positive reasons to use gaseous powered engines: Quieter engine noise level More convenient fuel source (natural gas) More emission complian

How large a generator do I need for my home or small business? Every home or small business is different. The size of the generator is based on the type of appliances, equipment, pumps, air-conditioners and other electrical devices requiring power. Your service panel is normally rated at 200 amps @ 240 volts and the average home uses approximately 140 to 160 amps of 240 volts power to operate everything at the same time. Your larger appliances (well pump, kitchen stove, water heater, electric dryer, electric heater and heat pump system) will typically use 240 volts power and the lights and other smaller appliances will use 120 volt power. It is important to consider this difference in doing the load calculations because the important calculation is to determine just how many amps and watts you will need. For example, if you want to operate your refrigerator (20 amps x 120 volts = 2400 watts), freezer (20 amps x 120 volts = 2400 watts), electric hot water heater (20 amps x 240 volts = 4800 watts), washer (20 amps x 120 volts = 2,400 watts) and electric dryer (30 amps x 240 volts = 7200 watts) all at the same time you will need approximately 19,200 watts to meet the breaker requirements for these appliances. In reality the breakers are typically oversized for safety by 10 to 15% and the above appliances will not all operate at peak at the same time and the above load can be handled with a 15,000 watt (15 kW) generator set (GenSet). The major appliances, pumps, or other motor driven devices that you plan to operate with your generator system need to be considered when calculating the minimum size of a generator. Sizing a generator system requires you to honestly assess your needs and wants. Generally you can cut through all this stuff with these simple rules. If you have 100 Amp service panel, use a 8-12 kW GenSet (use larger if you have air conditioning). If you have a 200 Amp service panel, use a 15-20 kW GenSet (again use the larger size if you have air conditioning or large well pump). If you have a 400 amp service panel, use a 30-50 kW GenSet (if you have lots of air conditioning or other larger loads use the large size in the range).

There are some other power requirements that will help you establish a minimum size generator system: 1) Well pumps usually require 2-3 times the run watts to start the pump. 2) Combination heat pump/air-conditioner systems are normally on 60 amp (14400 watts) breakers and use 30 amps (7200 watts) for the heat cycle and the same for the air-conditioning function. 3) Electric furnaces are typically on 50 amp breaker. (6,000 watts at 120 volts) 4) Hot water heaters normally use between 20 amps (4,500 watts) and 25 amps (6,000 watts) depending on the size and efficiency design 5) Electric kitchen stoves are usually on 50 amp (6,000 watts) breakers. 6) Air-conditioners come in a variety of sizes and ratings which need to be calculated based on the BTU output. A 2-ton unit is rated at 24,000 BTU's 20 amps (5000 watts) to start the unit and 15 amps (3,600 watts) to operate it. Single or Three Phase? Is a 3-phase generator suitable for the average homeowner or small business? Yes and No. Some manufacturers use an over-sized 12-wire 3-phase generator end for single-phase applications. This allows the generator system to be used for both single-phase and 3-phase applications. The advantage of using an over-sized generator in a 3-phase or single-phase application is to meet motor starting requirements without having to use an overly large diesel engine. For most residential applications are 1 phase (single phase) and using a 3 phase generator is a waste of money and fuel. If you have a 3 phase service you will need a 3 phase generator otherwise use a unit built as single phase. Be cautious, some dealers will try to sell you a 3 phase generator "strapped" for single phase. You will lose 30% of the generators output and use 30% more fuel to make single phase power. What is the function of the electronic controller on a GenSet? Most of the engine/generator controllers used today are digital and are designed to provide control of the generator set. (GenSet). The controller system monitors the operation of the engine and generator functions. Typical safety items include low oil pressure, high temperature, engine start over-crank, over/under frequency (speed), low coolant level etc. Modern digital controllers for residential or small business applications are typically a simplified LED indicators a start-stop button with or without autostart. If the generator has auto-start, the controller can be used to interface with an automatic transfer switch or inverter/battery system to start and stop automatically. Usually manual controls are provided on al generators including those with auto-start. Advanced controllers provides real time monitoring of volts, hertz and amperage in addition to the basic engine/generator safeties and auto-start functions. Complex controllers typically installed on larger generator systems provide engine safeties and shutdowns for low oil pressure, high temperature, engine start over-crank, over/under-speed, low coolant level and also have indicators for low fuel level, KVA output, KW output, power factor (PF),

engine & generator gauges in real time. Larger generators often have a communication capability for remote monitoring and starting. Can I use a portable generator for an automatic starting system? Generally No. Most portable generators do NOT have the capability to auto-start. The generator must have an electric starter, electric choke (for gasoline units) and the start and stop controls and safety sensors to be able to start and stop automatically. The cost of auto-start and safety equipment generally increases the price of portable equipment so much that no one would buy them, so they are not manufactured. What kind of generator should I purchase - gaseous or diesel? There are a number of factors to consider in evaluating the differences between a gaseous (natural gas or propane) powered engine. Do 3600 RPM diesel generators last as long as 1800 RPM GenSets? Generally the 1800 RPM engine speed will out last the 3600 RPM units. Most small diesel portable generators in the 3 kW to 6 kW class are air-cooled 3600 RPM engines are designed to keep the weight and cost down. Generally air cooled GenSets are for temporary use and have short lives. If you need a long term solution or have several outages a year or long outage times use a liquid cooled 1800 RPM GenSet What does the term "Wet Stacking" mean in a diesel engine? Diesel engines are designed to operate with a load. When a diesel engine operates considerably below the rated output level the engine can start to over-fuel or "Wet Stack". Diesel engines perform most efficiently in the 70-80% range of rated output. When an engine operates for a prolonged period of time below 40% of the rated output it begins to over-fuel. This is similar to driving a car in the City at slow speeds for long periods. Wet Stacking occurs because the injection tips began to carbonize and disrupt the fuel spray pattern. Commercial generator systems often have widely varying loads with some low output conditions often have wet stacking problems because of the diverse load applications and owners artificially load the generator with an automatic load bank. A load bank will place a "false" load on the generator system to keep the diesel engine properly loaded. Once a diesel engine begins to "wet stack" the only way to correct the problem is to load the engine for a couple of hours to burn off the excess fuel and clean up the engine. This is seldom necessary in a residential or commercial application. Generally, electronically controlled engines and engines with advanced emission systems are less likely to "wet stack". It is for this reason that proper sizing and design is important. GeneratorJoe can help you with all your sizing and design considerations. What kind of maintenance will my diesel generator need Diesel engines require routine maintenance for long-life service. The normal maintenance requirements are about the same as owning a diesel powered vehicle - oil, oil filter, air filter and fuel filter. In tropical

and cold climates it is advisable to have a water-fuel separation filter system installed. Water or moisture in diesel fuel can be damaging to a diesel engine because the water properties create advanced ignition and accelerated detonation. The engine will need an oil change every 250 to 500 hours depending on the dust conditions or annually in the case of standby generators. Change the oil filter when you change the oil. Air filters need to be changed when they appear dirty. Check air filters whenever you inspect the generator or change the oil. Fuel filters are normally changed every 250 to 300 hours depending on how clean the fuel is. Inspect fuel filters when you fill the tanks, during oil changes and any time you inspect the generator. If the generator has a service schedule, follow it. The generator end (AC alternator) will not require any service unless you live in a dusty environment. In dusty environments we recommend you use a high pressure (50 PSI) air hose and occasionally blow out the dust from the generator system. Dirt and heavy dust particles can cause shorts in the internal wiring coatings under the right conditions. How do transfer switches work A transfer switch is a box that only allows power to be supplied to the distribution panel from the utility or the generator system, but not both at the same time. There are basically three types of transfer switches to consider. 1) Manually operated panels providing 6 to 10 pre-selected circuits that can be used during any generator supplied power situation. See Reliance Controls switches. These types are used primarily for portable generators. 2) Manually operated Service rated (e.g. 100A, 200A, or 400A) NEMA-1(indoor rated) or NEMA-3R (outdoor rated), UL rated panels for either single or 3-phase applications. 3) Automatic operated Service rated panels. What is the difference between standby/emergency/maximum and prime/continuous duty applications? Most products have a "maximum" rating, also called standby and emergency rating. This value is the most that a generator can produce under normal conditions although it may still have some peak reserve for surges. The prime or continuous rating is the rating that the equipment should not exceed under normal running on a continuous basis. Even though small portables have both ratings that does not mean that they are designed for continuous use. A prime power generator must be 1800 RPM and liquid cooled. Any air cooled or 3600 RPM generator is a standby generator no matter what other dealers may tell you. Most residential generators are standby rated. You should use a prime rated, 1800 RPM, liquid cooled generator when the number of hours per year will exceed 500 and the use is on a regular basis. If you start the generator many times a year for short periods you may also need a prime power rated generator. You must use a prime power rated generator when the generator is used 24

hours per day and 7-days per week. If you use a standby generator in a prime power situation the generators life expectancy can be shortened considerably and the potential for premature failure is increased dramatically. Buying a GenSet rated for standby duty and using it for prime or prime continuous application is just dumb and will normally void your factory warranty as well. Your generator system should be considered a long-term investment and should be sized and selected properly. How are decibel levels calculated on generators? Most generator manufactures, but not all, calculate dBA levels at full load operation. The USA standard is based on the sound level at 21 feet (7 meters) and the European standard is based on the sound level at 23 feet but its close enough to compare. The calculation of dBA levels involves a complicated mathematical formula. The relative noise level is the best way to understand the relationship of one sound to another. Human conversation is 60 dBA. below are typical descriptions of sound levels. Take all sound levels provided by manufactures with a grain of salt. You cant tell the difference in 5 dBA without a lot of experience and a sound meter. See our noise table at NOISE. Industrial Quiet well designed enclosure with air-scoop and dense foam. 69 to 75 dBA - noticeable noise level at 10-feet / loud conversation at 21-feet. Residential Quiet well designed enclosure with air-scoops and foam. 64 to 68 dBA - quiet but noticeable at 10-feet / normal conversation at 21-feet. Super Quiet special sound attenuation enclosure normally with air-scoops and dense foam. 61 to 63 dBA - normal conversation at 10-feet / quiet operation at 21-feet. Ultra Quiet special sound attenuation design for rental fleets or residential applications. 56 to 60 dBA barely hear the unit operate at 10-feet / normal conversation at 10-feet. Entertainment Industry Quiet Special and expensive sound attenuated and designed GenSets. 50 to 55 dBA - barely hear the unit operate at 3-feet / normal conversation next to GenSet. For the average residential application, the residential levels shown about are adequate. Some engines tend to be noisier than others and will have some effect on the overall dBA rating of the unit. Obviously, a 10 kW generator is typically quieter than a 40 kW if all other conditions are equal. The abatement of noise in all GenSets is normally a function of the enclosure design, air-flow and the quality and type of insulation used. Front air-scoops are typically used to remove radiator sound. Special residential grade muffler systems are used to help reduce the engine noise. What is the difference between single and three phase? Single phase has only one phase using two wires and three phase has three phases using three or four wires. Generally homes are single phase and business are three phase. If you go out to your main breaker panel you can usually tell if you have a single or three phase service. Single phase is 120/240 and three phase can be 120/240, 120/208 or 277/480. There are other voltages but these are the most common