How to Find Good Diesel Generator Sets?

Choosing the right diesel generator can be overwhelming. The wrong choice might lead to inefficiency and costly maintenance. But with the right guidance, you can find the perfect solution for your needs. Here’s what you need to know.

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Diesel generators are critical for emergency power solutions. Knowing how to choose the right one ensures reliability and long-term savings.

Let’s dive deeper into the key factors to consider when choosing a diesel generator.

How Do I Choose a Diesel Generator Capacity ?

When selecting a diesel generator, capacity is one of the first things to consider. Choosing the right size is crucial to ensure that the generator can handle your needs without being over or under-sized.

The capacity of a diesel generator determines how much load it can power. Selecting the right capacity avoids wasting energy or underpowering your system.

Understanding Diesel Generator Capacity

The right capacity for a diesel generator depends on your specific power requirements. If you’re powering a small home or office, a smaller generator, say 20kVA to 50kVA, may be sufficient. However, larger industrial applications like telecom stations, power plants, or data centers might require generators in the range of 200kVA to kVA.

To avoid underperformance, it’s important to assess your load requirements carefully. Here’s a quick guide:

Power Requirements Generator Size Suitable Applications 1–40 kW 20 kVA – 50 kVA Small homes, small offices 40–120 kW 50 kVA – 150 kVA Medium businesses, retail shops 120–400 kW 150 kVA – 500 kVA Large businesses, telecom stations 400+ kW 500 kVA – kVA Industrial sites, power plants, data centers

You must also factor in the generator's load factor, which refers to the actual power demand over time. It’s essential to choose a generator with some extra capacity to handle peak demands without overloading.

Do Generators Need to Be Professionally Installed ?

Yes, professional installation is recommended when setting up a diesel generator. Even if the generator is easy to operate, proper installation ensures safety, efficiency, and optimal performance.

A professional installation ensures the generator works properly and complies with local regulations. It can prevent potential hazards and prolong the life of the unit.

Why Professional Installation is Critical

Installing a diesel generator involves several technical steps, such as connecting the electrical system, integrating with the main power supply, and ensuring proper grounding. If installed incorrectly, it can lead to serious risks, including electrical fires, overloading, and system failures.

Here’s what a professional installation typically includes:

• Site Assessment: A professional will evaluate the site to determine if the generator location is optimal for ventilation and safety.
• Electrical Wiring: Proper electrical connections ensure the generator delivers power efficiently and safely.
• Compliance with Regulations: A certified installer will make sure your setup complies with local codes and standards.
• System Integration: The generator will be integrated with your existing electrical systems, such as transfer switches or interlocks, to ensure seamless operation.

Additionally, professional installers often provide testing services to ensure the generator runs smoothly after installation, which can help avoid issues later.

Which is Better, Transfer Switch or Interlock?

When setting up a backup power solution, you may need to decide between using a transfer switch or an interlock. Both serve similar functions, but there are differences that might make one more suitable for your needs.

Transfer switches and interlocks help safely transfer power from the grid to a generator. However, the choice depends on your system’s complexity and safety requirements.

Transfer Switch vs. Interlock

Transfer Switch

A transfer switch is a device that automatically or manually switches between utility power and generator power when there is an outage. It isolates the generator from the grid and prevents backfeeding, which could cause dangerous electrical issues.

Here’s a breakdown of its advantages:

• Automatic or Manual Options: Depending on the model, it can either automatically switch power or be manually controlled.
• Safety Compliance: Transfer switches are designed to meet safety standards, ensuring safe operation when switching power.
• Capacity: They can handle large power loads, making them ideal for industrial and commercial applications.

Interlock

An interlock is a simpler device that physically locks the circuit breaker connected to the generator and the main breaker so that they cannot be operated simultaneously. It's a manual system, but it’s usually more cost-effective.

Advantages include:

• Cost-Effective: Interlocks are generally less expensive compared to transfer switches.
• Simpler Installation: Installation is usually less complex, making them a good choice for smaller applications.
• Basic Safety: They prevent backfeeding but require manual operation to switch between power sources.

In general, a transfer switch is better suited for larger or more critical systems where automatic switching is required. An interlock might be enough for smaller homes or businesses that don’t need automation.

How to Pick a Generator Transfer Switch?

Choosing the right transfer switch depends on your generator’s specifications and the type of power system you have. Here are a few factors to consider:

A properly selected transfer switch will ensure the safety and reliability of your backup power solution.

Key Factors to Consider When Picking a Transfer Switch

There are several critical factors when selecting a transfer switch:

1. Amp Rating: The transfer switch should match the generator’s output and the electrical load you need to power. Choose one with an amp rating that matches the generator's output capacity.
2. Type of Transfer Switch:
   • Automatic Transfer Switch (ATS): Switches automatically when a power failure is detected. Best for high-reliability systems.
   • Manual Transfer Switch (MTS): Requires manual operation to switch between power sources.
3. Safety Features: Look for a switch that includes surge protection, overload protection, and lockout features to prevent backfeeding.
4. Size and Space: Ensure the switch can fit in your electrical panel and has enough space for all necessary connections.
5. Certifications: Ensure that the transfer switch is certified according to local and international safety standards.

Choosing the right transfer switch requires careful planning to ensure it fits your specific needs and complies with regulatory standards. It’s often a good idea to consult with an expert when making this decision.

What Are the Three Types of Interlock ?

Interlocks are typically used in smaller systems, and they come in three main types. Here’s a quick overview of each:

Interlocks are important safety devices in systems with backup generators, and knowing the different types helps you make the right choice for your setup.

Understanding the Three Types of Interlock

1. Mechanical Interlock: This is the most basic type of interlock. It involves a physical mechanism that prevents both the generator and the main circuit breaker from being on at the same time. It’s typically simple and cost-effective but requires manual switching.

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2. Electronic Interlock: An electronic interlock uses sensors to detect the status of the main breaker and the generator breaker. It automatically disables one breaker if the other is turned on, offering an added layer of convenience and security.

3. Combination Interlock: This type combines both mechanical and electronic features, providing manual and automatic safety features. It’s ideal for more complex systems that require high reliability.

While mechanical interlocks are suitable for basic needs, electronic or combination interlocks may be more appropriate for critical applications, where safety and automation are crucial.

Conclusion

Finding a good diesel generator requires understanding your power needs, installation requirements, and safety systems. By carefully considering capacity, transfer switches, and interlocks, you can make an informed decision that will keep your operations running smoothly.

Buying a generator is typically a significant investment for a home or business owner. It’s also something most consumers don’t do very often, so there’s a lot of confusion around which fuel type to use (diesel, natural gas, propane), which brand is best (Cummins, MTU, Generac, Kohler, HIPOWER), and most especially, what size generator is appropriate.

To answer that last question, your first and best option is always to consult a certified electrician to assess your specific needs. However, if you opt to do it yourself, you can still make an informed generator purchase or rental by following a few basic guidelines. We’re laying those out in this guide to help you know how to determine what size generator you need.

Generator Classes: Residential vs. Industrial

You should already have an idea of what class of generator you need. If you’re a homeowner looking for backup or standby power, you need either a small, portable generator or a stationary standby generator. These sizes run from 2kW- watts or less for a recreational unit, up to about 50kW for a whole-house standby generator. These generators typically use a single-phase current, which are sufficient to power smaller equipment that don’t require constant, high-voltage power.

Industrial generators are available in a range of sizes, from around 20kW to well over 3MW. Larger business and industrial applications obviously require more capacity and thus often utilize three-phase motors for higher power. Office buildings, manufacturing facilities, data centers, and building complexes such as shopping malls, educational institutions, and living centers all require larger-capacity generators. This is the case whether it’s regarding primary power supply or emergency back-up power generation.

How to Size a Generator

The basic generator sizing formula goes like this: 

1. Form a list of all items that will be powered.
2. Determine the starting wattage (energy needed to turn it on) and running wattage (energy needed to operate it) for each piece of equipment. These figures are typically inscribed somewhere on the equipment itself, as well as recorded in the owner’s manual.
3. Calculate your total power requirement by adding up these kW or KVA figures.

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For equipment rated in amperes, you can convert amps to watts with the following formula:

• For resistive loads (most common type): Wattage = amperes x volts
• For reactive loads: Wattage = amperes x volts x load factor

Load factor is the ratio of your electric energy use in kilowatt-hours to your peak demand in kilowatts. You can calculate it by consulting your utility bill for data and using it in the following formula:

• Total kWh for the previous month / (your peak demand for the period x 30 days x 24 hours)

Even if you lose the manual, you should be able to find wattage details online. However, if you can’t determine a piece of equipment’s power draw figures, you can use a ballpark number. For example, these are the starting and running figures for some common tools and electronics:

Once you know the estimated wattage needed, the generator size is easier to choose. Whatever number you come up with, choose a generator with a capacity that’s 10-20% larger than your requirement. This will give you some leeway when and if you update your equipment and end up needing more power as a result. It also helps you manage “de-rating,” or under performance of the generator compared to its manufacturer-claimed abilities due to adverse operating conditions, such as extreme temperatures or high altitudes.

Buying a Single Generator vs. Paralleling

If your power needs are large enough, you may wonder whether it’s better to go with a single, huge diesel generator, or split the burden between two or more smaller generators. For example, instead of a kW generator, you could install three 400kW generators. This is called paralleling, and it can be a great option in the right circumstances. Here’s why:

#1. Greater flexibility. It’s very likely the reason you’re buying a generator at all is the additional reliability, a hedge against an interrupted power supply causing a slowdown or halt to your business’s operations. With multiple generators, you don’t have to worry if one has to be shut down for maintenance. You simply shift the burden to the others and keep right on working. 

With just one generator, if it has to stop, so do you. 

#2. Can be more cost-effective. Obviously the economics will vary widely depending on brands, new vs. used generators, prices in your geographic location, etc. But all things being equal, once you breach a certain generator size, it becomes more economical to parallel than use a single unit. Specifically, once you go over the sizes of gas or diesel engines mass-produced for use in cars, as well, those engines are harder to come by and are thus more expensive. And the engine comprises more than half the cost of a generator. 

The threshold for diesel engines is 600kW and for gas engines it’s 150kW. 

#3. Can be more practical. Depending on your physical space, it may be easier to fit two or three parallel generators into a room than one oversized unit. Among large commercial generators, smaller capacities can mean the difference in 25 or more square feet per unit. 

#4. Easier on the generators. Load sharing among two or more generators can extend the life of each generator and avoid the risk of overburdening a single unit. For continuous usage, loads up to 80% generator capacity are ideal.

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Generator Sizing and Fuel Consumption

In the same way a -level truck uses more fuel than a , larger generators consume fuel faster than smaller units. This is important to remember when “running the numbers” on what a new or used generator may cost. Not only do you have to refuel larger generators more often, it may be necessary to store extra fuel on-site, precipitating the need for additional storage tanks.  

For this reason, when it comes to residential generators, Consumer Reports recommends getting the smallest portable or home standby generator that meets your needs to limit the amount of fuel you have to store to run it. 

For industrial-strength generators, consult our approximate diesel fuel consumption chart to estimate how much fuel you’ll burn in a particular generator size operated at either a quarter-, half-, three-quarter, or full load. 

Why It’s Crucial to Choose the Right Generator Size

It may be tempting to skimp on the size of your generator, especially when doing so might save you a couple thousand dollars. However, selecting a generator that’s too small for your applications is a recipe for disaster. Not only can you damage the appliances and devices pulling power from the generator, you can harm the generator itself.

Here are some more benefits of erring on the side of a generator that’s too powerful, as opposed to too weak:

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• Increased usable life of the generator
• Consistent production performance
• Limited incidence of capacity overloads
• Limited incidence of unexpected system failures
• Reduced likelihood of asset damage
• Increased personnel safety
• Decreased risk of overheating and electrical fires
• Reduction in frequency and cost of maintenance
• Increased ease and speed of maintenance