Which generator to buy: Prime Power? Standby Power? Continuous Power?

This is the first question to ask before you buy a generator: a) If you have no supply of electricity from a grid source or Public Supply Company and you need it for your facility for 12 hours a day: We recommend a Prime Power generator. Note: If you have specific continuous base load or motor starting requirements contact us with full details. b) If you have no supply of electricity from a grid source or Public Supply Company and you need a generator for your home for 12 hours a day: We recommend a Prime Power generator. c) If you have a break in Electricity supply for up to six hours a day (Domestic or industrial premises): We recommend a Standby generator. d) If you have a constant supply of electricity, but it is essential you have an emergency back up for maximum of 500 hours a year (approximately 1.5 hour a day): We recommend a Standby Generator or Maximum Power Generator (available only for few sizes, also limited to Maximum 500 hours use in a year). e) If you are a Contractor and need electricity for your site for a maximum of 6 hours a day (maximum 2000 hours a year): We recommend a Standby power generator. f) If you are a contractor and need electricity on site for up to 12 hours a day (maximum 3000 hours a year): We recommend a Prime Power generator. g) If you need a generator for your leisure time (maximum 500 hours a year): We recommend a cheap petrol portable generator. h) If your grid source or Public Supply Company electricity is unstable and you need a steady current for your computers or other sensitive equipment: We recommend portable generator with an automatic voltage regulator control system in the alternator. It may also be appropriate to have an engine equipped with electronic governing for close frequency (Hz) control.

What size of generator do you need?

The Generating Set size can be determined by the total demand of your powered equipment. Below you can find the typical energy requirement for each electrical appliance in your house. This will help you to obtain a general idea of your total load. As stated we strongly recommend that before you make your final decision to purchase you seek advice from a local Electrical Engineer or Consultant who is best qualified to assist you in choosing the right size and may have equipment available to monitor your load demand over a period of time to determine your maximum and minimum demand.

Remember: buying a Generator that provides lower capacity than needed - may damage both the engine and the alternator. It should also be noted that engine driven generators need to be loaded to a minimum of 50% of rated output at all times in order to prevent mechanical damage, even if this means running unnecessary appliances to make up the demand. Please learn more about this subject in our FAQ "under load" and "over load". Please see our separate estimating table for load calculation. Diesel, Petrol, Kerosene or Gas? Choosing the Generator engine type is a sensative issue combining capital investment costs and operating costs. The cheapest operating costs are for Gas fuelled generators. In sizes up to 100 KW Gas generators can be up to 30% more expensive than Diesel fuelled generators with the same output. If Gas is available and you are going to operate your generator for more then 2000 hours a year, this can be the most cost effective solution Gas is also much more environment friendly. Choosing the Generator engine type is a sensative issue combining capital investment costs and operating costs. The cheapest operating costs are for Gas fuelled generators. In sizes up to 100 KW Gas generators can be up to 30% more expensive than Diesel fuelled generators with the same output. If Gas is available and you are going to operate your generator for more then 2000 hours a year, this can be the most cost effective solution Gas is also much more environment friendly. Kerosene engines are not expensive to buy and have comparatively low running costs. They are limited in output generally not exceeding 5KVA.An additional advantage in using Kerosene fuel is that it is less volatile and thus much safer than Petrol. Petrol Engines are the cheapest to purchase and the most expensive to operate. If you need a Generator to operate for up to three hours a day, they are a good choice. In general, Petrol fuelled generators are limited to maximum output of 20KVA and minimum speed of 3000 RPM. Diesel Generators are commonly available with outputs from 5 KVA up to 2500 KVA. They are significantly cheaper to operate and maintain compared to Petrol, but more expensive then Petrol engines. If you need a generator for more then 3 hours a day, or a minimum of 1500 hours annually, we recommend that you to buy a Diesel Generator.

Engine speeds of 1500/1800 rpm or 3000/3600rpm? Engines in generating set packages operate in two fixed speed bands: Low speed: 1500rpm for 50Hz or 1800rpm for 60Hz High speed: 3000rpm for 50Hz or 3600rpm for 60Hz. High speed engines are cheaper to buy but their life span is significantly shorter. They are also limited to providing a maximum generator electrical output of 35kva. They are acceptable for Stand By use of up to 2000 hours in a year or when finances are limited. Low speed engines are more expensive, but have greater longeivity. They are the better choice when operational requirements are above 1000 hours annually. Base Load, Prime or standby? These ratings are defined by international standards. Base load ratings are for generator operation continuously, without breaks other than for fuelling and maintenance. They are usually capable of sustaining a 10% overl0ad output for 1 hour in every 12 hours of operation. Prime power ratings are 10% above base load outputs and relate to generators operating under continuous conditions but with consistently variable loads. . They are usually capable of sustaining a 10% overl0ad output for 1 hour in every 12 hours of operation. Standby power ratings offer 10% more output than prime power subject to variable load and limited to a fixed running period annually which is determined by the Engine Manufacturer. These operating periods vary considerably between different brands of engine. No overload is allowed. The KVA, KW rating of generators is based on engine and alternator outputs at Normal Temperatures and Pressures (N.T.P.) generally defined as 25 Centigrade at sea level. If the Generator is required to operate in high temperatures, at high altitude or in a combination of these conditions, a derate in output performance may occur. If you have no mains electricity at all you need a base load generator. This is a generator that can run from one service to the other non-stop. You can use a prime power rated Generator at up to 90% of its capacity. If you live in a place where the public supply of electricity is not reliable and you need back for up to 12 hours a day buy a generator with a prime power rating. If you need a Generator on standby for not more than 500 hours a year, or you need to provide a generator as a back up by law use a standby rated machine Some Manufacturers have special lines of Generators for these purposes but they are very strict about using these sets for No More then 500 hours a year.

Check the Manufactures recommendations. You might lose your guarantee and warranty for the engine if you use a prime power rated engine in a base load application. Single phase or Three Phase? If you are going to use your generator in one place and have access to mains supply (residential, factory or business office), and you have the funds - buy a Generator with automatic start and an automatic change over system. Automatic Mains Failure systems are reliable and they are competitively priced. If you use your set for a construction site or temporary placement, use a manual start generator. In many cases, by law you must use automatic AMF systems.(hospitals, clinics, banks, cold rooms, etc). What brand of engine is suitable? All well known engine brands are good and reliable. The main question when choosing a brand of engine is: Can I obtain local service and spares support and is the initial capital cost competitive. First check local service support, then the cost - a Generator without good local back up service is not a cost effective solution. What alternator is suitable? The most popular alternators in the market are: Newage Stamford, Meccalte, Leroy Somer and Marathon. All of these brands are very reliable and are built for long term operation. The key questions here yet again are, is the prime cost competitive and what is the availability of product support locally. The main exchange parts that you may need for Alternators are automatic voltage regulators and diodes. These items are available in most countries for all of the above brands.

Why do I need a generator?

There are a few reasons why businesses and home owners will make a decision to purchase a generator:

Mains electricity is not available

There is insufficient mains power supply to meet requirements To protect against the possibility of losing mains power, which could cause economic loss, loss of power, loss of lighting, lose of life support equipment, loss of production, loss of data storage and loss of products, human life or livestock.

What is the difference between an electric or manual recoil generator?

These days recoil start generators are easy to start. It depends on what you would prefer. Manual Recoil Start Generators are hand operated, whereby you start the generator with a pulling motion on a cord. Electric Start Generators are key started with a battery attached. Electric start generators are ideal for people who just dont have the strength or power to start a recoil start generator. In most cases a recoil only start without electric key start on a portable diesel generating set is not recommended.

What is the difference between a petrol or diesel generator?

It really depends on were you use the generator or how often you use it: Petrol generators are primarily designed for not running for extended periods of time at maximum load. In addition, petrol generators, because of their simpler design, are less expensive that diesel engines. Diesel generators are primary designed to operate between 60% and 100% load for extended periods of time and are more fuel efficient.

What makes up a standard portable generating set?

Powerlite Portable Generators comprise of the following parts: Engine Alternator Heavy Duty Frame Anti Vibration Mounts

Options include Wheel & Handle Roll Frame Earth Leakage Protection Workcover Spec 4 Gang Protection Module Workcover Spec 6 Gang Protection Module Earth Stake Kit Centre Lift Bar 18 Litre Fuel Tank extended operation Dry Battery Welding Cable Kits

What do you need to know if you are installing a stand by / prime power generating set or a portable generating set to a fixed location?
Location: should be easily accessible for service and maintenance. If a generator is located outside, it will need to be fully enclosed, so the weather cant affect it anyway. Canopies are ideal for generators outside. Mounting: Generators needed to be placed on a level base, preferably concrete and should have anti vibration mounts fitted. If a generator is being installed on soil or on a roof you should consult a civil engineer. Ventilation & Cooling: A generator should only be used in a well ventilated area to ensure the generator stays cool and to remove excess heat produced through engine combustion. Exhaust: Where installed internally, the exhaust must be piped external to the building as exhaust fumes are toxic and dangerous.

Can a generator be wired into my home electrical system, so when the mains power is cut off the generator will cut straight in?
Yes, generators can be wired into your home electrical system, so when the mains power is cut, the generator automatically kicks in. This is possible with the use of an Automatic Transfer Switch (ATS). Wiring a generator should only be done by a qualified electrician. Manual Transfer Switch (MTS) can also be used, this is where you need to manually start the generator after the mains power has been cut off then switch the power

supply from mains to generator supply. The reverse will need to happen when a stable mains power supply has been returned.

How long will a generator run for on a tank of fuel?

This depends on several things - the engine size of the generating set plus what load the generating set is operating at to determine the engines fuel consumption. Then divide this into the fuel tank capacity to give you the anticipated run time between refueling.

Where can I get warranty work done on my generator if needed?

We have a very comprehensive service department located at Kings Park or we can advise you of the closest service agent to where you are located.

What happens if I overload a generator?

Generating sets should never be overloaded, but are designed to take an overload condition of a very short time during start up of large element motors. If a set is running for long periods of time with an overload (that is a rating above the maximum rating of the set) there are various things that may occur:

Overheating of the engine Overheating of the alternator windings & components Oil viscosity (thickness) breakdown, which results in low oil pressure and most probable costly engine failure A shortening of the working life of the generator

What happens if I underload a generator?

Engines are designed to operate under varying load, which ranges from maximum to minimum. In relation to diesel generators it is recommended they run at a minimum of 60% load, this insures the engine runs at maximum efficiency. A diesel engine that operates on a light load for long durations runs the risk of glazing the cylinder bore. Should this occur the engine will not hold high loads, it will use excess oil, and blue smoke will be visible from the exhaust. The engine then may require costly major repairs. Petrol engines are normally not effected by light load running.

What type of oil does a generator use? Oil is a major factor effecting the performance and service life of a generator. Petrol Generators- use 4-stroke automotive detergent oil. Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SJ or later. Always check the API service label on the oil container to be sure it includes the letters SJ or later. SAE 10W is recommended. Diesel Generators - use API service classification CD or higher ... please refer to your engine operation manual for engine oil viscosity. Running a generator with low oil level can cause engine damage and this damage is not covered by warranty. Change the engine oil regularly - your generator oil should be changed after 20 hours of initial operation or at the end of the first month and every 3 months or 100 hours thereafter. When changing your oil, drain the oil while the engine is warm, as later it may be difficult to drain the oil completely. Please Note: Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize, or shorten engine life on the generator. Prevent dirt and debris from contaminating the engine oil. Carefully clean the oil cap / dipstick and the surrounding area before you remove the cap. Never mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil. Never overfill. Always refer to the operation manual of the engine, supplied with the generator for the correct oil type required.

What type of petrol does a generator use?

Petrol generators use regular unleaded petrol containing no more than 10% ethanol (E10) or 5% methanol. If you use fuels with content of ethanol or methanol greater than shown above this may cause starting and/or performance problems. It may also damage metal, rubber and plastic parts of the fuel system. Engine damage or performance problems that result from using a fuel with percentages of ethanol or methanol greater than shown above are not covered under warranty. The ideal generator size is one that is correctly matched to power all the things you want to run at the same time.

If it is too big, not only will it be more expensive to purchase, but it will not necessarily run as efficiently as the correctly matched size. If it is too small, some of your equipment may not get it maximum output, and its lifespan may be reduced.

1. FIND THE AVERAGE WATTS

All electrical appliances and motors, should have (by law), an electrical rating plate with the power and electrical requirements shown on it. Find the Watt rating for each appliance you want to use. Note: kW x 1000 = Watts HP x 746 = Watts

See the Average Watts Table below for the Watt rating of some typical

appliances. Average Watts Table For Industrial Electric Motors, the power shown on the motor rating plate does not take into account the motor efficiency or starting load use the figure shown in the Average Watts Table for electric motors.

2. ADD THEM UP

Add up the Watts for each appliance or motor you are going to run at the same time. For example: 5 1 1 1 x x x x 100 Watt Lights Kettle Toaster 550 Watt Motor requiring 2200 Average Watts = = = = = 500 Watts 1800 Watts 600 Watts 2200 Watts 5100 Watts

TOTAL AVERAGE WATTS

Note : If you need to operate a generator for more than 30 minutes, add 10% to your Average Watts total.

3. CHOOSE YOUR GENERATOR

You need a generator with Watts equal to or slightly higher than your Average Total Watts. Each of our Powerlite Generator types comes in a full range of Watts, from compact petrol 2200 Watt to commercial scale diesel 6000 Watt. Just click on your preferred generator type below to see our comprehensive product ranges.

Click your prefered generator type to see all our power options:

Petrol Diesel Inverter Welder Generators

Need even more power? See these ranges:

Stand By / Prime Power Generators PTO / Tractor Generators

Generator Related Glossary

AC Alternate Current Air Cooled Engine Air Cooled Engine Alternator Alternator Alternating electrical current.

Engines that are cooled by air. These engines have no radiator. A machine that converts mechanical energy to electrical energy.

An electronics control system that monitors and detects when the main AMF electricity supply fails and automatically starts the generator, switching Automatic the supply source. When the main electricity supply is restored it Mains Failure switches the supply back and stops the Generator. Ampere A unit of electrical current. Ampere A Meter that reads the ampere output on each phase of a Generator at Ampere Meter any point in time. There are generally three Ampere Meters in each Ampere Meter Generator panel. In general: older electronic method used in control and measuring Analogue systems. An analog or analogue signal is any variable signal continuous Analogue in both time and amplitude. It differs from a digital signal in that small fluctuations in the signal are meaningful. ATS Automatic A switch that is controlled by the AMF mains detection system, and Transfer changes automatically between the Grid supply and Generator supply. Switch Automatic Start Automatic start of a generator that is controlled by an electronic system. Automatic Start There are two major components to a genset, the Engine and the Alternator. The Engine supplies power, rated in KW or HP and the Alternator provides voltage and current and is usually rated in KVA, volts and Power Factor. For the best performance, it is important to select the correct engine and alternator and couple them together rather than assume a standard set. This can result in the most commercial and best performing result. The Engine must supply all the power required by the installation, this includes work power and loss power. If the engine is not large enough to supply all the power demanded, it will slow and the frequency will drop. In sizing the engine for an installation, it is necessary to determine the maximum KW demand and the continuous KW demand and ensure that the engine is suitably rated.

The engine has a continuous output rating and has a short term maximum power rating. The short term rating can be used to provide the energy for starting motors, but often the overload capacity is not sufficient to provide the full start requirement without over sizing the engine. During start, the motor will draw up to its rated KW (particularly as it approaches full speed) plus a high copper loss in the stator. If the copper loss is 5% at full load, and the motor is started with a DOL (Full voltage) starter, it will draw Locked Rotor Current during start The Locked Rotor Current could be in the order of 700% of the rated current of the motor, so the copper loss will be 7 x 7 x 5% of the rated power of the motor, or just under 250% of the motor rating!! The same applies to the cable losses. If the cable loss is 5%, then under full voltage starting, the power demanded from the engine could be another 250%. Additionally, the copper loss of the alternator could add another 250% power demand on the engine. Now we have a power demand of around 850% of the motor rating. Reduced voltage starting will reduce the start current and thereby the power demand on the engine. With very low inertia loads, the inertia of the engine and alternator may be sufficient to supply the power to start the load, but there will still be a significant frequency droop. The engine is fitted with a governor which is a means of speed regulation. The governor will adjust the throttle on the engine to keep the speed and output frequency constant. Severe overloads will often result in a droop in speed during start, and a surge in speed as the load comes off. It is best to have a relatively slow load application to allow the governor to track the load. If the engine is a diesel engine, it is preferable to try to size the engine so that the continuous operating power is reasonable high. Continuous operation at light load will increase the required maintenance on the engine plus increase the fuel consumption. The Alternator supplies the current to the load. The Alternator has a finite internal impedance and the voltage is regulated by an AVR (Automatic Voltage Regulator) which controls the excitation applied to the alternator. There is a finite maximum excitation that can be applied and this limits the maximum current that the alternator can supply. When the alternator is fully excited, the excitation is saturated, additional load will cause the voltage to drop quickly. The alternator tends towards current limiting. The AVR monitors the output voltage either by single phase, half wave, peak reading or by three phase full wave averaging detection systems. The single phase method is usually connected across two phases but is only measuring on the peak of one half cycle per cycle. The three phase averaging method has six times the effective sample rate and is able to respond much quicker to any variations and provide a more stable output in response to step and transient loads. Where a single phase AVR is used, it is best to avoid getting too close to saturation of the excitation system, as there can be hunting of the AVR as it tries to regulate the output voltage as the load drops off. Apply a larger "safety margin" in alternator sizing when using a single phase AVR. Alternators have a rated short term overload capacity and this can supply the start current

to motors. Some alternators can be fitted with excitation boost kits to further increase the short term overload capacity. Typically, the short term overload capacity of an alternator is in the region of 130% to 200%. It is important to determine the maximum that can be achieved reliably. If this information is not available, use 120%. Soft Starters are one of the better ways of minimising the start current without any steps or transients. This can lead to the best reduction in voltage disturbance on the genset, but there are some issues. The peak reading AVR can become more confused with the use of a soft starter due to the harmonic currents during start. Some peak reading AVRs may be unstable when used with soft starters. The Altenator has a very finite impedance and because of this, the output voltage waveform will be distorted by the discontinuous current waveform drawn by the SCRs. This is not a problem except that the effect can be a level of phase modulation of the output waveform. The soft starter can become confused and try to track the phase modulation, making it worse etc and the net result can be instability or imbalance in the start current. Some soft starters will loose control when used on a marginally sized genset and cause excess current and KW for little or no gain in start torque. When this happens, the generator will commonly go unstable and shut down. This is not a problem will all soft starters. It is most likely to occur in starters using fast feedback algorithms internally, such as "true torque control". Changing the start mode, or start settings may overcome the problem, or changing the soft starter type may also overcome the problem. Ensure that the soft starter is suitable for use on marginally sized gensets. Motor Rated Current = Rated full load current of the motor Rated Voltage = Rated voltage of the motor Rated Power = Rated shaft power of the motor. Start Current = Current required to start the machine. This current is a function of the motor, the driven load and the starting method used. For Full voltage starting (DOL) the start current is equal to the locked rotor current of the motor, irrespective of the load being started. Cable Voltage Drop. = Total voltage drop between the Alternator and the motor. For genset applications, this should be less than 5% in order to minimise the power dissipated during start. This will have a major bearing on the Engine rating. Motor Efficiency = Rated full load efficiency of the motor. Alternator Alternator Voltage = Output voltage of the alternator Alternator Efficiency = rated full load efficiency of the alternator (excluding the excitation energy) Engine Overload Capacity = Rated short term load capacity of the Engine. Typically 130% to 200% of the continuous rating. Alternator Overload Capacity = Rated short term load capacity of the alternator. Typically 130% to 200% of the continuous rating.