Diesel Generator Solutions Hub

The most comprehensive generator troubleshooting, installation, maintenance & repair guide in East Africa. No one else provides this depth of technical knowledge.

Generator Installation Guide

Complete step-by-step installation procedures from site preparation to commissioning. Following these guidelines ensures safe, reliable operation and warranty compliance.

🏗️

Site Preparation & Foundation

Step 1 of 6

1

Survey the installation site for proper ventilation (minimum 1.5m clearance all sides)

⚠️ Critical Step - Do not skip
2

Calculate foundation requirements: Mass = 2× Generator weight minimum

⚠️ Critical Step - Do not skip
3

Ensure concrete curing time: 28 days for full strength, 7 days minimum

4

Install anti-vibration mounts (AVM) - spring or rubber isolators based on RPM

⚠️ Critical Step - Do not skip
5

Verify floor load capacity: Typically 500-1500 kg/m² for generators

6

Plan exhaust routing: Maximum 3 bends, proper rain cap, thermal expansion allowance

⚠️ Critical Step - Do not skip

💡 Pro Tip: Foundation mass should be 2-5× the generator weight. For 500kVA (3,500kg), foundation should be 7,000-17,500kg concrete.

⚡

Electrical Connections

Step 2 of 6

1

Size cables using IEE regulations: I = P/(√3 × V × PF × Eff) for 3-phase

⚠️ Critical Step - Do not skip
2

Install properly rated circuit breakers: MCCB at generator, ACB at main panel

⚠️ Critical Step - Do not skip
3

Connect neutral-earth bond at ONE point only (generator or main panel)

⚠️ Critical Step - Do not skip
4

Verify phase sequence (R-Y-B) using phase rotation meter before paralleling

⚠️ Critical Step - Do not skip
5

Install surge protection devices (SPD) Type 1+2 at generator output

6

Test insulation resistance: >1MΩ @ 500V DC for LV, >100MΩ for MV

⚠️ Critical Step - Do not skip

💡 Pro Tip: Cable sizing formula: Cross-section (mm²) = (1.732 × I × L × ρ) / (ΔV × 1000) where ρ=0.0175 for copper.

⛽

Fuel System Installation

Step 3 of 6

1

Install day tank within 3m of generator, main tank within 30m maximum

2

Size fuel lines: Minimum 10mm ID for up to 100kVA, 15mm for up to 500kVA

⚠️ Critical Step - Do not skip
3

Install fuel water separator and primary filter before engine fuel filter

⚠️ Critical Step - Do not skip
4

Ensure return line is larger than supply (prevents vapor lock)

⚠️ Critical Step - Do not skip
5

Install emergency fuel shutoff valve accessible from outside generator room

⚠️ Critical Step - Do not skip
6

Test fuel system: Prime, check for leaks, verify fuel lift pump pressure (2-5 PSI)

⚠️ Critical Step - Do not skip

💡 Pro Tip: Fuel consumption estimate: 0.25-0.30 liters per kWh. A 200kVA @ 80% load ≈ 40 liters/hour.

❄️

Cooling System Setup

Step 4 of 6

1

Calculate radiator airflow: Minimum 8-12 m³/min per 100kW for air-cooled

⚠️ Critical Step - Do not skip
2

Install remote radiator if needed: Max head 15m, use glycol mix 30-50%

3

Size ventilation openings: Intake = 0.5 × radiator area, Exhaust = 1.5 × radiator area

⚠️ Critical Step - Do not skip
4

Install motorized louvers with generator start interlock

5

Fill coolant: 50% water + 50% ethylene glycol, add DCA4 additive

⚠️ Critical Step - Do not skip
6

Pressure test cooling system: 1.0-1.4 bar, check for leaks

⚠️ Critical Step - Do not skip

💡 Pro Tip: Room temperature should stay below 40°C. Calculate: Heat rejection (kW) = Rated Power × 0.3 for cooling needs.

💨

Exhaust System Installation

Step 5 of 6

1

Size exhaust pipe: Minimum equal to engine exhaust outlet, larger for long runs

⚠️ Critical Step - Do not skip
2

Install flexible connector at engine to absorb vibration (stainless bellows)

⚠️ Critical Step - Do not skip
3

Support exhaust every 1.5-2m, allow for thermal expansion (10mm per 3m)

⚠️ Critical Step - Do not skip
4

Maintain maximum backpressure: 3-4 kPa for naturally aspirated, 6-7 kPa for turbo

⚠️ Critical Step - Do not skip
5

Install rain cap and spark arrestor (required for enclosed areas)

6

Wrap exhaust with insulation in occupied areas (surface temp <60°C)

💡 Pro Tip: Excessive backpressure causes: Power loss (1% per 0.25 kPa over limit), increased fuel consumption, engine damage.

🎛️

Control Panel & ATS Installation

Step 6 of 6

1

Mount control panel at eye level, protected from vibration and moisture

2

Wire all sensors: Oil pressure, water temp, fuel level, battery voltage, RPM pickup

⚠️ Critical Step - Do not skip
3

Configure ATS: Mains fail delay 5-10s, transfer time <100ms, retransfer delay 5-30min

⚠️ Critical Step - Do not skip
4

Set protection parameters: Overspeed 110%, undervoltage 85%, overcurrent 110%

⚠️ Critical Step - Do not skip
5

Test emergency stop circuit: Must stop engine and disable start

⚠️ Critical Step - Do not skip
6

Commission remote monitoring if required: GSM, Ethernet, Modbus

💡 Pro Tip: DeepSea & PowerWizard controllers: Always backup configuration before commissioning. Use PC software for parameter changes.

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