Remote Site Generator Sets

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Remote Site Extended Run Generator Set
Lubrication System
Cooling System
Fuel System
Air Intake System
DC Electrical System
AC Electrical System
Control and Metering
Fuel Tank and Skid Base
Shutdowns and Alarms

This is a "typical" custom design/build project for a remote site application.

The RER (Remote Extended Run) generator set is designed to provide reliable operation in remote locations, and to extend regular service intervals without any sacrifice in performance or overall equipment life.

Some of the generator set's systems are unique to this usage. They include our Long Run Oil System™, oversize fuel tank, specially-designed cooling system, and enclosure designed to allow sufficient air to flow to the unit even if one side should become blocked (ice storm, leaf build-up etc.)
The genset has satellite communications to allow remote monitoring, testing and control.
Long Run Oil System™
The oil reservoir capacity has been enlarged to allow the engine to operate for a period of 3,000 hours. Consideration was given to the normal oil consumption of the engine under any load conditions, as well as to the maximum oil consumption expected as the engine wears.

An oil suction strainer extends into the reservoir to sufficient depth to ensure that the engine will to continue to have adequate lubrication throughout the extended service interval. Baffles, located in the oil reservoir, provide the engine with warmed oil in cold operating conditions.

Other features of the oiling system include a heat exchanger to normalise the oil temperature with the coolant bypass circuit. In high ambient operating conditions this will cool the oil, while in low ambient temperatures the heat exchanger will warm the oil even when the thermostat is closed. Large capacity, full flow, lube oil filters (2) are easily accessed for servicing. An internal oil pressure relief valve regulates engine oil pressure. As well, the duplex oil filter assembly is equipped with individual relief valves on the filters. Should one filter become plugged, the other will remain operational.

The initial oil fill is made with synthetic oil. This oil is compatible with non-synthetic oils. It is strongly recommended that the same, or equal lubricating oil be used when topping up or replacing the oil.

When the oil and filters are being changed, at 3,000 hour intervals, the spin-on filter elements should be pre-filled with oil before installation. After filling the oil reservoir, the set should be run up for five minutes, shut down and the oil level should be brought up to the full mark on the dipstick. DO NOT OVERFILL THE OIL RESERVOIR. The oil will expand as it warms so there needs to be air space above the oil level. Filling the reservoir above the high mark indicated on the dipstick will cause the engine to shut down due to "high oil level" fault. WHEN SETTING UP THE GENERATOR SET FOR USE, IT SHOULD BE INSTALLED AS LEVEL AS POSSIBLE. THIS PREVENTS A FALSE "HIGH" OR "LOW" LEVEL SHUTDOWN FAULT.

Engine with front pan

Cooling System
The cooling system consists of two electrically operated fans, a thermostat for engine coolant, an electrically driven coolant circulation pump and various components to signal and monitor the cooling system. These elements are matched to provide the engine with proper cooling even under conditions of severe heat or cold.

Essentially, the flow circuit consists of a circulating pump drawing coolant, (50/50 water/low silicate antifreeze) from the radiator and discharging the coolant through the engine's cooling passages. A thermostat in the return to the radiator regulates the engine's temperature. A bypass circuit redirects some coolant through a heat exchanger to warm or cool the engine oil. When the engine reaches its normal operating temperature the thermostat allows most of the coolant flow to return to the radiator where waste heat is exchanged to atmosphere by one or both of the electric fans, as required.

The primary fan, located in the engine enclosure, is powered by the same 115 VAC supply circuit as the circulating pump. This low flow fan maintains the engine's temperature even in extremely cold operating conditions. A high flow, secondary fan is thermostatically controlled. It cycles on or off, as dictated by ambient temperature and engine load conditions. The large volume cooling system allows for degradation caused by foreign materials (within the system or on radiant surfaces).

It is recommended that the antifreeze mix be flushed and replaced every two years or 10,000 hours, whichever occurs first. A pre-mixed solution, suitable for diesel engines may be used. A 50/50 mix of low silicate antifreeze and de-ionized water is acceptable. An air bleed vent is located on the top of the heat exchanger to help purge air from the system when refilling (see photo of overflow bottle).

Each time the set is serviced (3000 hours) the fans should be inspected for dust or dirt clogging the motors. As well, the hoses, clamps, water pump seal and all fittings should be checked for leakage.

Other cooling system items include an overflow bottle for the radiator's coolant, which should be kept at the indicated level. The secondary fan motor, located in the plenum chamber, is cooled by the fan's air flow. This motor should be cleaned annually with compressed air. (More often if operated in dusty conditions) The radiator cap, the engine's thermostat and the circulating pump's seal should be replaced every 10,000 hours.

Fuel System
A single fuel filter is located "upstream" from the mechanical fuel transfer pump. There is a priming bulb located on the filter head. The element should be replaced every 3000 hours. Any water or dirt should be drained from the sediment bowl. Use only the exact replacement element part number.

Care should always be taken when refuelling that no water or dirt enters the fuel storage. The main tank on the base frame is angled slightly to allow water to drain away from the engine's suction and return fittings which are located near the bottom of the fuel tank. If necessary, any water can be drained from the tank via the drain valve.
Air Intake System

A pre-filter, designed to remove 95% of moderate to heavy dust is located on the air filter inlet. The air cleaner element should be replaced every 10,000 hours. More frequent element replacement may be required in dusty conditions. Tree needles and some seeds can be a problem to both the cooling and air intake systems. If the set is operating in an area where these circumstances might be found, check and service the air cleaner, cooling fans and intake and exhaust louvers as required.

DC Electrical System
There are two, paralleled, 12 volt lead acid batteries for the starting circuit. An automatic, 3 amp, battery charger, located in the rear control panel, maintains both batteries. When the set is running there is very little DC load. Do not add DC loads such as lighting without contacting the manufacturer to ensure adequate charging is available. Frequent starting cycles may also require an increase in battery charger output.

The enclosure is designed to allow sufficient air to flow to the unit even if one side should become blocked. (Ice storm, leaf build-up etc.) The panels at the radiator end are removable for servicing the main cooling fan and motor. Always replace these panels after servicing.

The enclosure is "rodent proof", as supplied. It is very important, both for safety and for operating reasons, that all sheet metal and guarding remains properly fastened and in good condition. The powder coated outer and inner surfaces protect the metal from deterioration. Touch up scratches and chips with automotive enamel paint.
AC Electrical Equipment
The generator is brushless and has a solid state automatic voltage regulator. Generally, no generator maintenance is required before the engine is due for major overhaul.

A main circuit breaker protects the generator from electrical faults and branch circuit breakers are provided on all circuits.

All components of the electrical system are bonded and a grounding lug is supplied. The unit must be grounded in accordance with local regulations.

Control and Metering
A control module is installed which provides engine and generator monitoring functions. As, well the control module supplies signals to various engine subsystem tasks. For details, the specific manual is provided. Wiring details are shown on the wiring schematics.

A reset feature can be used to count down hours to the engine's service intervals. As well, the control module stores accumulated kilowatt hours and total running time.

Fault monitoring, with adjustable parameters, allows the control module to alert a designated operator, via wireless modem should an alarm or critical fault occur.

Fuel Tank and Skid Base
The fuel tank is a single wall reservoir with approximately 500 US gallons of capacity. A 2" NPT filler neck is surrounded by a splash guard. One fuel level sender is provided to pre-alarm low fuel level. Locks are provided to protect the contents.

Extreme care should be exercised when filling the tank to prevent foreign materials from entering the fuel system. Under normal warming and cooling cycles, condensation will form within the tank. This water will settle and can be drained off the bottom of the tank via the drain valve supplied.

Shutdowns and Alarms
Situations that would result in an engine failure are monitored and, at a predetermined point, will result in the shutdown of the generator set. These conditions are; low oil level, high oil level, low oil pressure, high coolant temperature, engine over-speed and engine under-speed.

In addition to the shutdown points there are predetermined alarm parameters. At the alarm point, a signal can be generated to notify the operators of potentially dangerous conditions. These conditions include; low fuel level, over-cranking of the starting motor, sender failure (oil pressure, coolant temperature), high or low speed signal, low battery voltage, battery over-voltage, generator overload and scheduled maintenance due.