How to heat the generator in winter for a good start. How to start a diesel generator in extreme cold? Corrosion protection of moving parts
25.09.2015
Gasoline - the only panacea in the cold?
A fairly common opinion among the majority of users of diesel generators is the assertion that these units, unlike gasoline ones, do not start well in winter in severe frost. In reality, this is not entirely true. A properly installed power plant, subject to all operating conditions and refueling with high-quality fuel, does not cause problems with operation and start-up even in severe frosts. In order not to encounter these problems and not be left without electricity and heating in winter, country cottage, or in your home, you need to follow some tips, follow simple rules and take a number of measures that can make it easier to start a diesel generator in the cold season. It is precisely these issues that this article is devoted to.
Type and quality of fuel - the first step to success
Most of those who have ever serviced a power plant will agree with the opinion that often the main problems with starting an engine in "hard" conditions are related to the physico-chemical composition and properties of the fuel, and not design features power unit. This is due to the fact that a decrease in air temperature inevitably leads to an increase in the viscosity of the fuel mixture and changing its balance. As a result, the fuel is sprayed worse in the working cylinders and it becomes more difficult to start the engine.
With regard to this problem, it would not be out of place to recall that there are two types of diesel fuel - summer and winter. Accordingly, in the cold season, the power plant must be refueled with a winter diesel engine. This question must be clarified at the gas station where you purchase fuel, since many unscrupulous gas stations continue to sell summer diesel fuel even with the onset of cold weather.
What is the danger of getting such fuel into the engine at an outdoor temperature of about -10 ° C? Answer: paraffin crystals precipitate in the fuel mixture, as a result of which the fuel filter of the device and its lines become clogged and fail. Moreover, this process can occur so quickly that even a running power plant can stall.
In order to never encounter such troubles, it is necessary to develop a rule to buy only high-quality fuel and never save on it, so you should only use the services of trusted gas stations of well-known companies (often they have stricter fuel quality control). Remember that low quality diesel fuel at low temperatures, it tends to turn into a jelly-like mass. The situation can be aggravated when the diesel engine was diluted with water (which is also not uncommon at domestic gas stations) - in this case, the generator may not start even in summer.
Additives
A fairly popular tool that increases the efficiency of the fuel mixture in winter period is the use of special additives to thin it, called antigels. In extreme cases, when there are no such substances at hand, but it is urgent to start the diesel generator (the fuel has thickened), you can add a little gasoline or kerosene to the tank, but you must remember that by doing so you slightly increase engine wear. A safe concentration is considered to be 10-15% of lighter fuel relative to the total volume of diesel fuel in the tank.
Installation of preheater
Very often, many craftsmen warm up a frozen engine with blowtorch. This method has two disadvantages: the first is that it is not always convenient to perform such a procedure, especially in severe frost, when the station is installed in open space, and the power unit is located at the bottom of the power plant. The second is not always safe, so doing such operations better specialist. A real alternative here is an autonomous heater. So, the presence of a built-in pre-heating system allows you to once and for all get rid of problems with starting a diesel generator in any conditions, regardless of the climatic zone.
Considering the peculiarities of our climate, many modern manufacturers of this equipment, whose products are oriented to the markets of the CIS countries and other territories with cold winters, are well aware of the problems faced by domestic users, therefore they supply their own stations with pre-heating systems for the engine, crankcase and spark plugs. This device installed in the engine cooling circuit, which contributes to the heating of the oil in the crankcase, as well as the cooling system fluid. The power and cost of such a heater directly depends on the power of your generator, the volume and weight of its cooling system. There are two types of these devices - electric and diesel. The former are intended for installation in power plants, used as backup or additional sources of electricity, and the latter are for use in powerful diesel generators that act as the main source of energy supply.
Most preheaters are designed to operate in several basic modes - constant maintenance operating temperature at a predetermined level and warming up on a timer. Frequent starting of a diesel engine in the "cold start" mode can significantly reduce its resource. The presence of a built-in preheater in the power plant allows not only to save the resource of the autonomous power source, but to extend the life of the generator as a whole. These heaters are connected to a common electrical network, but, despite this, they are always ready for operation.
Installation of diesel generators in containers
Another no less popular way to safely operate diesel electrical installations in winter is to install them in specialized containers. In fact, this design of generators has several advantages at once. First of all, a heating system and other additional equipment can be installed inside such a container for the "life support" and normal operation of the generator in very coldy, as well as maintenance personnel, it is much more convenient to carry out repair and service work.
In addition, specialized containers contribute to the constant movement and frequent transportation of the power plant from place to place by any type of transport, which makes them quite maneuverable despite their considerable size. It should also be noted that in addition to ensuring continuous uninterrupted operation of the unit and maintaining it in working area necessary temperature regime and the most optimal climatic conditions, the container implements an equally important function for a diesel-type generator - effective sound insulation. Installed in a container diesel power station will start in any weather, so this type of execution is best suited for operation in "hard" conditions.
If the generator is portable, then it can be brought into heat, for example, in a room in order to pre-warm before starting. As you know, there are power plants with various options start - manual, electric starter and automation. In everyday life, the first two types are most often used. Based on practice, it can be noted that an electric starter-based starting system can bring more problems, since this electronic device very capricious behaves in the cold. A guaranteed start of a generator equipped only with an electric starter is provided in most cases at a temperature of + 5 ° C, and then with a new battery. With a mechanical cable or handle to start the power plant, the chances are slightly higher. Mechanical start with almost 100% guarantee is provided at a temperature of -5°C.
Let's talk right away. We are not interested in hybrid generators due to the fact that hybrid generators use both gasoline and liquefied gas, by nature and calorific value they are so similar that there will be no problems other than an incorrectly selected reduction gear and a small evaporation area in the cylinder, due to which freezing will occur. On the other hand, these generators are very difficult to automate, and then starting and stopping lies on the shoulders of the owner, who will change the type of fuel and start the generator manually.
IN this case we are talking about generators in automatic mode, which must be started without human intervention, and, therefore, other requirements for starting, maximum operating time and special means, which should help to carry out the launch in the winter.
So, in the winter, 3 main reasons affect the launch:
- good battery,
- good oil,
- quality fuel.
Of course, all these requirements can be ideal, but subject to the use of a low-quality engine or improper maintenance, they will not help. In one of the articles I talked about some of the nuances of engines (How to choose a reliable engine?), But now this is not about that.
What happens at startup?
Suppose we have a perfectly tuned, charged generator with a good, powerful charged battery. The temperature in winter "floats", it can be from -1 to -38 and the oil, once frozen, retains this temperature and excess viscosity for a very long time. So what, you ask, is it:
a) did not freeze and did not shackle everything inside,
b) the contact area of the engine parts is small and the engine should spin, despite the fact that the oil now resembles more candied honey than a liquid.
And you will be right, but try pulling the manual starter and you will feel some serious resistance. It comes from one small piece called a decompressor - here it is, located on a large gear.
A small mechanism designed to make it easier to start the engine from a manual starter plays a cruel joke in winter and harms starting more than it helps. On the one hand, it is supposed to facilitate starting due to the fact that the exhaust valve is ajar, but in practice it either blocks the opening of the exhaust valve or prevents the decompressor from working.
Despite the fact that the engine rotates and there is a spark, it does not start, because there is no initial ignition in the cylinder - the poor mixture that gets there just as quietly flies out.
In the case of an open decompressor, the engine simply does not pick up speed, because the starter power is insufficient, it is designed for use in an engine with a decompressor, a battery is selected for the same condition, which is overwhelmingly gel, 9 a / h, and when this gel solidifies, it is unlikely will be able to provide more than 5-7 launch attempts.
This is where proposals begin to equip the battery and engine with heating, etc. and so on, but no one, mind you, NOBODY will give a guarantee of starting in the winter and at the same time will not remind you that good heating costs like a whole generator, and it will also constantly consume electricity, since these parts need 200-300 Watts per hour, otherwise it will only be calming without any effect.
As a result, the conclusion suggests itself one: if you do not use a branded engine, the materials of which are selected with high quality, the battery is suitable for the task, fill in old or low-quality gasoline, operate an unadjusted or universal gas system, then in minus temperature you will run into problems when starting.
As another reminder, I list engine manufacturers that can be described as proprietary: Honda, B&S, Kohler, Robin-Subaru, Mitsubishi, Generac. Here, in principle, is the entire list of engines that are on the market in Russia, the rest are more or less “labels”, that is, engines assembled in China with a sticker of some kind of “manufacturer”. I wrote about this in more detail in the article (see link).
But there is also a way out, as I have already described, structurally, the power plants on the market are not designed to work in cold climates. The Russian market is too small for China to develop generators for us. But, given the experience of 14 years of work and production, we have assembled power plants for cold climates, which are specifically designed to start in deep minus, and there is no magic. We just took ANOTHER engine and completed it taking into account the launch experience and the conditions of Russia.
1. Power plant engine GG6-SV DOES NOT HAVE A DECOMPRESSOR. It was removed. Along with this, a more powerful starter was needed, and, look, the GG6-SV starter is almost 4 times more powerful than similar stations (!). The first photo shows the starter GG-6SV and nearby the starter of any other station with a power of 5 to 7 kW. On the second - the same thing - for clarity, mounted on the engine.
Modern gasoline, diesel and gas generators are reliable devices that are equipped with several levels of protection.
The presence of special elements allows you to ensure the protection of equipment and prevent its failure. However, even the most advanced and secure system is not able to work stably if it is not started correctly. Only by understanding how to start the generator, you can ensure the effective functioning of the equipment in any conditions.
Proper start-up and use of the device reduces the possibility of breakdowns due to human error and guarantees the longevity of the generator.
Preparatory work
After unpacking the power plant, it must be carefully examined to make sure that there are no breakages or defects that could have been obtained during transportation. Before you start the generator, you need to make sure that all components are connected to each other.
When buying a new generator, it comes with instructions from the manufacturer, which you need to read. Even if you are an experienced specialist who has already dealt with energy generating devices, it is possible that this model is distinguished by its special properties. The generator is a high-tech device, and almost every model on the market has its own nuances that you need to pay attention to during use.
Before starting the generator, it will be necessary to fill the device with a suitable and high-quality oil. Given the fact that the generator consumes a minimum amount of oil, it is best not to save money and buy proven brands, since it is the quality of the oil that plays a major role in ensuring the durability of the equipment. In the process of choosing oil, it is necessary to take into account the characteristics of the temperature regime of the area where the generator will be used.
Running different types of generator
Starting petrol, diesel, gas generator should be made taking into account the characteristics of each individual species. Only strict adherence to the rules will allow the correct launch and not harm the equipment.
Launch types
To turn on any unit, you need to take into account the features of the starting system. Featured on modern market generators are distinguished by the following engine starting systems:
A mechanical system that is very often seen in gasoline and diesel power plants. In order to start such a generator, you need to pull the handle of the cord towards you until you feel resistance. There are times when the power unit refuses to start the first time. You just need to repeat the procedure until the generator starts working. If an inverter generator is installed, then some other manipulations will need to be carried out. Before starting the generator, you should connect the power and only then pull the handle and open the air damper; 
Starting with an electric starter. Before starting a generator of this type, it is imperative to make sure that the terminal is securely fastened. You should also make sure that the battery is installed and ready for use. The fact is that not all manufacturers equip their units with built-in batteries, as a result of which they have to be purchased separately;
Automatic start. Distinctive feature units with a self-start function is that they turn on immediately after a power outage. Before switching the load, it is necessary to let the unit run in idle state, so that in the future it can provide stable power generation.
Using a diesel generator in cold weather
Starting a diesel generator in frosty winter is a complex process that requires strict adherence to the rules. Otherwise, the unit may be damaged. When trying to start the generator low temperatures a number of problems can arise, which can only be solved in a complex way.
The first way to solve this problem is to install a preheater on the cooling circuit of the power plant. This appliance is used to heat the liquid in the cooling system, which may freeze due to low temperature.
The second option is more practical: it consists in placing the diesel generator in a special container that protects the unit from excessive cold. If the device is in such a container, then it will not be difficult to start it even in the most severe frosts. A distinctive advantage of such containers is that they not only protect from the cold, but also significantly reduce the level of noise produced. That is why such a start of a diesel generator in winter in frost is considered the best option.
Features of starting a gas generator
Before starting the generator gas type, it is extremely important to make sure that there is enough oil, and also to disconnect the load.
After all the necessary manipulations are performed, you should:
Start the valve that is responsible for the gas supply;
Turn on the power plant;
Close the air damper.
All other manipulations fully coincide with those that must be done when working with other types of devices.
Engine break-in features
If the first start-up of the power unit is carried out, then it is necessary to run it in, which will positively affect the durability of the device. The essence of the break-in is to turn on the equipment at 50% power and let it work for two hours. At the same time, the oil level should be constantly monitored, thanks to which it will also be possible to find out how much oil the generator actually consumes during its operation. Such equipment cannot be idle long time, as this negatively affects the time of its uninterrupted operation.
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To do this, it is recommended to carry out maintenance (TO) of the generator: completely drain all the remaining fuel from the gas tank and carburetor. Be sure to clean the filter, check the candles. Carry out an oil change, because. spent lubricant mixtures, solidifying in the crankcase, contaminate it, which may lead to difficulty starting in the future. By unscrewing the spark plug, a small amount of oil is injected into the combustion chamber. Also, about 150 ml of engine oil is poured into an empty gas tank and the generator is tilted in different directions, distributed along the inner walls of the tank. Anti-corrosion protection can be applied to the outer casing. Pack the generator in a box and store it in a dry, preferably heated room or in special all-weather containers, casings. Do not store fuel in stock for more than 30 days, because. the octane number of gasoline decreases, the fuel loses the necessary properties.
Generator storage recommendations may vary by different manufacturers. Preservation instructions can be found in the accompanying technical documents.
So you shouldn't store the generator!
Otherwise, there will be big problems with the launch!
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