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  • Diesel Engine Wet Stacking: Causes, Consequences & Prevention
    2025/06/22
    Diesel Engine Wet Stacking: Causes, Consequences, and Prevention Introduction Diesel-powered generators are renowned for their reliability and fuel efficiency, outperforming gasoline, propane, and natural gas units in both longevity and operating costs. However, to deliver on that promise, they must be run under sufficient load. Operating a diesel generator “light” or idling for long periods leads to a phenomenon called wet stacking, sometimes nicknamed “engine slobber.” Left unchecked, wet stacking degrades performance, increases maintenance costs, and can even void the manufacturer’s warranty. In this post, you’ll learn: What wet stacking is, and why only diesel engines experience itThe root causes, from low-load operation to fuel-system faultsHow wet stacking damages cylinders, rings, injectors, oil, and exhaust systemsPractical prevention strategies, including correct sizing and load-bankingEarly-stage remediation techniques you can perform yourselfWhen to call in certified Perkins or Caterpillar techniciansWarranty implications and why prevention is the best protection What Is Wet Stacking? Definition:Wet stacking occurs when unburned fuel and heavy hydrocarbons accumulate in the exhaust system and cylinder walls of a diesel engine. Rather than fully combusting, extra fuel condenses into oily black sludge (“wet stack”) that drips from the exhaust or turbocharger housing. How to Recognize It: Visible Signs: Dark, oily deposits around the exhaust outlet or downpipe; black residue on nearby surfaces.Audible/Sensory Cues: A strong diesel smell after shutdown; popping or back-firing at startup.Engine Behaviour: Blue-gray smoke on acceleration; lower exhaust temperatures at idle. Primary Causes Low-Load Operation: Running below 30–60% of rated capacity prevents cylinders from reaching optimal combustion temperature.Oversized Units: Generators sized for peak demand but seldom loaded will chronically under-utilize capacity.Combustion Pressure & Sealing Issues: Low cylinder temperatures cause ring glazing, which reduces seal effectiveness and worsens incomplete combustion.Fuel-System Faults: Over-fueling: injection timing or metering set too rich.Worn or mis-set injectors: leaks or poor spray patterns.Incorrect air–fuel ratio: blocked air filters or intake restrictions. Environmental and Usage Factors: cold-weather idling, infrequent exercise under load, and moisture accumulation. Consequences & Damage Cylinder & Ring Glazing Glazing smooths out honing patterns on cylinder walls, preventing oil-control rings from wiping excess oil and leading to blow-by and accelerated wear. Injector & Valve Fouling Sludge deposits on injectors and valves disrupt spray patterns and airflow, impairing combustion and raising emissions. Oil Dilution & Corrosion Unburned fuel washes into the crankcase, diluting oil, lowering viscosity, and forming corrosive acids that damage bearings and camshafts. Exhaust & Turbocharger Impact Oily deposits in turbochargers and exhaust piping increase back-pressure, reduce efficiency, and clog after-treatment devices. Performance & Emissions Rough running, stalling, or hard startingHigher fuel consumption for the same powerFailed emissions systems risk regulatory non-compliance Prevention Strategies Regular Load-Banking: Frequency: at least monthlyProcedure: run at 30–75% load for 30–60 minutes to burn off deposits Proper Sizing: Select a generator whose typical load sits above 40% of capacity; consider paralleling smaller units if demand is intermittent.Consistent Real-World Operation: Utilize real loads (HVAC, pumps, lighting) rather than extended idle periods; simulate loads as necessary.Fuel Quality & Stabilization: Use ultra-low-sulphur diesel, keep tanks topped up, and add stabilizers for storage over 30 days.Routine Maintenance: Follow Perkins or Caterpillar recommended intervals for oil and filter changes, air filter replacements, injector and valve checks, and cooling system inspections. Modern Engine Considerations Advanced common-rail injection, charge-air cooling, and electronic controls reduce, but do not eliminate, the risk of wet stacking. Proper loading remains essential. Shorter, more frequent light-load tests for some applications.Quarterly complete load-bank tests for standby units with low real demand. Remediation of Early-Stage Wet Stacking Heavy-Load Run-Up: Operate at a load of≥ 75% for 1–2 hours; monitor smoke and exhaust temperatures.Visual Inspection: Check for reduced sludge at the exhaust and turbo housing; test the oil for fuel dilution.Repeat as Needed: Multiple cycles may be required to restore normal combustion. When to Call the Experts If symptoms persist, such as deep glazing, repeated oil dilution, or chronically low exhaust temperatures, schedule professional service. Certified Perkins or Caterpillar technicians can hone cylinders, replace rings, calibrate injectors, and rebuild turbos to minimize downtime and cost. Warranty ...
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  • Perkins Engine Warranty – 6000 Hours!
    2025/06/17
    Episode Description

    Aurora Generators has teamed up with Perkins® to deliver an offer that redefines peace of mind for backup-power owners. In this episode, we break down how the new promotion upgrades every 10 kW and 13 kW Aurora diesel generator with FREE Perkins Platinum Protection—doubling engine coverage to four years or 6000 hours. You will hear why extending the standard 2-year/3 000-hour warranty matters for homes, farms, tele-sites, and off-grid cabins that cannot afford downtime.

    We start with the fundamentals: what makes a Perkins liquid-cooled diesel so different from gasoline, propane, or air-cooled units? Lower fuel burn (≈ approximately 0.5 gal/hr at 10 kW), rugged 20,000-hour life-to-overhaul, and whisper-quiet operation, thanks to oversized radiators and sound-attenuated enclosures. Then we dive into the details of Platinum Protection itself: zero deductibles, 100 % parts-and-labour coverage, factory-trained technicians who come to you, and complete transferability if you ever sell the set. For most buyers, that package would cost about a few hundred dollars, but Aurora is absorbing the fee during this launch window.

    Aurora will automatically register your warranty for an Aurora Diesel Generator powered by Perkins engines. You just need to keep to the normal maintenance schedule. The rest of the generator (alternator, controls, tank, enclosure) continues to be backed by Aurora’s five-year comprehensive warranty.

    Whether you’re designing an off-grid solar system, safeguarding a business, or just tired of unreliable portable generators, this conversation explains why now is the smartest—and least expensive—time to step up to an Aurora Perkins diesel generator set.

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  • PTO Generators
    2025/06/13
    What Is a PTO Generator and Who Uses Them?

    A Power Take-Off (PTO) generator is a mobile electrical power unit that draws its mechanical energy directly from the PTO shaft of an agricultural tractor, truck, or other heavy-duty vehicle. Instead of relying on a self-contained engine, a PTO generator harnesses the engine power of the host vehicle—making it an efficient, space-saving solution for on-site electricity needs.

    How PTO Generators Work
    • Connection: The generator’s input shaft is linked to the vehicle’s PTO output via a splined coupling.
    • Drive: As the vehicle’s engine runs and engages the PTO (typically at 540 or 1,000 RPM), it spins the generator’s rotor.
    • Generation: The rotor’s motion within the stator windings produces alternating current (AC), which is then conditioned by on-board regulation equipment to provide stable, usable power.
    Key Features & Benefits
    • Compact Design: Without an integrated engine, PTO generators are smaller and lighter than standalone units.
    • Cost Efficiency: Shared use of the host vehicle’s fuel and maintenance schedule reduces total cost of ownership.
    • Flexibility: Operators can switch the generator between multiple tractors or trucks, adapting to seasonal or evolving workload demands.
    • Rapid Deployment: Hook-up to the vehicle’s PTO is straightforward, allowing power on-demand for short-term tasks.
    Who Uses PTO Generators?
    • Farmers & Agricultural ContractorsRunning irrigation pumps, grain augers, milking parlors, or fencing equipment in fields without fixed power.
    • Construction & Site ContractorsPowering lighting towers, compressors, and small machinery on remote job sites without hauling separate generators.
    • Utility & Maintenance CrewsProviding spot power for tools and lighting during roadside or rail repairs using truck-mounted PTO units.
    • Event & Rental ServicesSupplying temporary power for outdoor concerts, fairs, and emergency shelters via rented tractors or trucks.
    Is a PTO Generator Right for You?

    If you already operate tractors or heavy vehicles and need intermittent or remote power—especially in agricultural, construction, or utility contexts—a PTO-driven generator may be the most economical and adaptable choice. By leveraging existing equipment, you gain dependable electricity with minimal additional investment and upkeep.

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  • Why Won’t My Portable Generator Start?
    2025/06/03
    Portable gas-powered generators are indispensable during power outages, camping trips, or when working in remote areas. But what happens when you go to start your generator, and nothing happens? One of the most common culprits is fuel-related issues. In this blog, we’ll explore the top fuel-related reasons your gas generator may not start and offer practical tips for troubleshooting and prevention. 1. Fuel Degradation: The #1 Starting Problem Gasoline doesn’t last forever. Fuel can start to degrade in as little as 30 days, especially when exposed to air and temperature fluctuations. As gasoline ages, it oxidizes and forms gums and varnish that clog the carburetor’s tiny jets and passages, restricting fuel flow to the engine. Signs of bad fuel: Strong, sour odourDarker colour than fresh gasolineSluggish or no engine turnover Solution: Drain old fuel from the tank and carburetor bowl.Refill with fresh gasoline.Add a fuel stabilizer, such as STA-BIL, to extend fuel life, especially before storage.After adding stabilizer, run the generator for a few minutes to circulate it throughout the system. 2. Water Contamination in Fuel Condensation in fuel tanks or contaminated storage containers can introduce water into your gasoline. Water does not burn and can prevent proper combustion or even corrode internal components. Symptoms: Sputtering engineFailure to startWhite smoke or steam from the exhaust Solution: Drain the tank completely.Refill with fresh, dry fuel.Consider using a fuel-water separator or ethanol treatment if you're in humid environments. 3. Ethanol-Blended Gasoline Problems Most pump gas today contains up to 10% ethanol. While legal and widespread, ethanol has downsides in small engines: Attracts moisture, leading to phase separationAccelerates corrosion in metal componentsForms gummy deposits when left unused Best practices: Use ethanol-free gasoline if available (often sold at marinas or premium gas stations).Always use a fuel stabilizer designed to combat ethanol-related issues.Run your generator dry or drain the carburetor if you plan to store it for long periods. 4. Clogged or Gummed-Up Carburetor Even if you’ve put fresh gas in the tank, residue from degraded fuel may already be clogging the carburetor. This restricts the air-fuel mixture needed for combustion. Symptoms: Generator starts, then stallsNo start despite a full tank and a working spark plug Solution: Remove the carburetor and clean it thoroughly.Spray carburetor cleaner into jets and passageways.Use compressed air to clear debris.If needed, install a carb rebuild kit. 5. Fuel Valve or Fuel Line Blockage A closed or clogged fuel valve will prevent gasoline from reaching the carburetor, even if your tank is full. Quick checks: Ensure the fuel valve is open.Remove the fuel line to confirm that gasoline flows freely.Replace fuel filters or lines if clogged or brittle. 6. The Generator Is Flooded With Fuel Repeatedly trying to start your generator, especially with the choke on, can flood the engine. Too much fuel in the combustion chamber prevents ignition. Solution: Let the generator sit for 10–15 minutes to allow excess fuel to evaporate.Avoid repeated cranking with the choke fully on.Ensure proper choke settings when starting. Preventive Maintenance: Your Best Defence Routine generator maintenance can prevent most fuel-related starting issues: Change the oil as recommendedReplace the spark plug annually or after extended useClean the air filter regularlyDrain the carburetor if storing for more than a monthRun the generator monthly to keep fuel flowing and prevent magnetism loss Most portable generator starting problems are simple to fix, especially when the issue is fuel-related. Regular maintenance, fresh gasoline, and proper storage can prevent most headaches. By focusing on fuel quality and carburetor health, you can ensure your generator is ready when you need it most.
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  • Fixing Portable Generators – No Output Power
    2025/06/03
    Why Your Generator Runs But Produces No Power – The Role of Residual Magnetism If your portable generator runs but doesn’t produce power, you’re not alone. This is one of the most common generator troubleshooting issues reported by homeowners, contractors, and RV owners. Understanding why a generator runs but has no voltage output is essential for restoring power quickly, especially when backup power is critical. One of the primary culprits? Loss of residual magnetism. What Is Residual Magnetism and Why Does It Matter? All generators rely on magnetism to create electricity. When your generator starts, a small amount of magnetism—known as residual magnetism—is used to generate an initial low voltage, which then feeds into the excitation system to produce full power. Without this leftover magnetism from a previous run, the generator has no way to “kick-start” the process of power generation. “If residual magnetism is lost, your generator will produce no power at startup.” — Why Does My Generator Run, but Not Produce Electricity? Common Causes: Why Residual Magnetism Is Lost If you’re wondering why your generator is running but not generating electricity, here are some common causes of residual magnetism loss: Prolonged storage or inactivityShutting down with a load connectedRunning the generator without a load for too longTransport vibration (common with new generators)Fuel starvation under load (e.g., generator runs out of fuel mid-use) “Loss of residual magnetism may be caused by having a connected load when the generator is shut off, or by running your generator for too long with no load.” — Fixing Portable Generators with No Power Other Common Reasons a Generator Produces No Power While residual magnetism is the most common issue, it’s not the only reason a generator has no voltage output: ✅ Tripped breaker or GFCI Always verify that all breakers are reset and functioning properly.✅ Faulty AVR (Automatic Voltage Regulator) A failed AVR can prevent voltage build-up.✅ Damaged capacitors Some generators use a capacitor instead of an AVR to build voltage.✅ Worn carbon brushes or slip rings These are essential for transferring power from the rotor to the stator.✅ Excitation winding issues Broken or grounded windings prevent the generator from energizing. How to Restore Power: Flashing a Generator When residual magnetism is gone, it can often be restored using a process called flashing the generator. Here are two proven methods: 1. The 12V Battery Method Disconnect the AVR or excitation wire (consult your generator manual).Briefly apply 12V DC from a car battery to the field windings.This jumpstarts the magnetic field needed for power production. “The 12-Volt Generator Battery Method involves applying battery voltage to the excitation circuit to rebuild magnetism.” — Fixing Portable Generators – No Power 2. The Electric Drill Trick Plug a corded drill into the generator.Start the generator with the drill’s trigger pressed.Spin the drill chuck backwards by hand. This sends a small current back into the generator. “The corded drill trick works as a way to field-flash a generator and restore power output.” Preventing Future Power Loss To ensure your generator always produces power, follow these best practices: ✅ Run the generator under load regularly✅ Disconnect all loads before shutdown✅ Avoid fuel starvation while under load✅ Store and transport your generator carefully to avoid vibration damage “Always run your generator with a load and disconnect that load before you turn the generator off.” When to Call a Generator Repair Professional If your generator still runs but produces no electricity after flashing or basic troubleshooting, it’s time to call a qualified technician. Complex electrical issues—such as excitation circuit failures or AVR problems—often require professional tools and expertise. Final Thoughts Whether it’s a portable generator not producing voltage, a diesel generator not generating power, or a home backup generator with zero output, the most common cause is loss of residual magnetism—a small, often overlooked part of the generator’s startup sequence. With basic knowledge of flashing techniques, a multimeter, and a few safety precautions, you can often restore your generator’s functionality. But if that doesn’t work, Aurora Generators is here to help. Our team is experienced in diagnosing and repairing power generation issues and can walk you through troubleshooting or recommend qualified service providers. Related Searches People Ask: Why is my generator running but not producing electricity?How do I flash my generator to restore power?What causes loss of residual magnetism in generators?How to fix a generator that runs but has no output voltage?Generator stopped producing power under load – what now?
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  • DynaGen Wiring Harnesses
    2025/06/02
    Why Use a Pre-Made DynaGen Wiring Harness?

    Using a DynaGen pre-fabricated wiring harness offers several significant advantages:

    • Saves Time and Effort Harnesses like DWG1476, DWG1477, and DWG1478 come with standard connectors that match DynaGen controller terminals, making installation quick and hassle-free.
    • Reduces Wiring Errors Each wire is labelled, colour-coded and properly terminated, minimizing the risk of incorrect connections that could damage the controller or cause system failures.
    • Clean, Professional Installation Pre-bundled cables reduce clutter, improve serviceability, and enhance the overall appearance of the wiring setup.
    • Ensures Compatibility These harnesses are designed explicitly for DynaGen controllers, including the TG350, TG410, TE600, and TG600, ensuring correct pin assignments and reliable operation.
    • Enables Advanced Features Advanced models, such as the DWG1477, support features like CANbus, Modbus, and sensor integration (e.g., Sensata oil pressure sensors), streamlining the installation and configuration of complex systems.

    Pre-terminated harnesses are particularly useful in mobile or outdoor generator setups, where durability, uptime, and ease of service are crucial. These harnesses are standard accessories across multiple DynaGen controller lines, and their use is typically recommended in wiring diagrams and manuals for models like the TE350, TE410, TG350, and TG410.

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  • Introduction to DynaGen Controllers
    2025/06/02

    In this episode, we are discussing generator instrumentation, protection, and control. Aurora Generators is an authorized distributor of DynaGen engine and generator controllers. We deliver across North America and fully support DynaGen products.

    Find out what makes these generator controllers so tough and why your generator needs one.

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  • Gas vs Diesel Generators
    2025/06/02
    Summary

    Diesel generators have long been the workhorse of critical-power applications—from hospitals and data centers to remote off-grid installations—because of fundamental differences in their thermodynamics, mechanical design, and operational characteristics.

    1. Higher Thermal Efficiency and Lower Fuel Cost
    • Compression Ignition vs. Spark Ignition Diesel engines compress air to very high pressures (ratios of 14:1 to 22:1), heating it until injected fuel auto-ignites. Gasoline engines use spark plugs at lower compression (8:1–12:1), limiting efficiency.
    • Higher Energy Density Diesel fuel delivers about 38.6 MJ per liter versus 34.8 MJ/L for gasoline, yielding more work per volume.
    • Brake Specific Fuel Consumption (BSFC) Modern diesel gensets achieve ~185–200 g/kWh, while small gasoline units often exceed 300 g/kWh—burning 30–40% less fuel per kWh.
    2. Robust Mechanical Design and Reduced Maintenance
    • Heavy-Duty Construction Engine blocks and major components are made of thick cast iron or forged steel to withstand high pressures, unlike lighter aluminum in gasoline units.
    • Simplified Auxiliary Systems No spark plugs, distributors, or carburetors—just sealed, precision fuel injectors. Fewer wear items mean fewer maintenance tasks.
    • Longer Service Intervals Industrial diesels often go 2,000–4,000 hours between major overhauls (10,000+ hours on large standby units), compared to 500–1,000 hours for gasoline engines.
    3. Extended Longevity
    • Lower Engine Speeds Running at 1,500 RPM (50 Hz) or 1,800 RPM (60 Hz) cuts cumulative wear by 30–50% versus 2,000–4,000 RPM in gasoline engines.
    • Oil Cooling and Filtration High-capacity sumps, full-flow and bypass filters, and oil coolers keep contamination low and extend component life.
    • Tough Wear Surfaces Hardened liners and coated piston skirts resist scuffing, delivering 10–30× the lifespan of similar gasoline engines.
    4. Suitability for Heavy-Duty and Continuous Applications
    • High Torque Output Peak torque at low RPM handles heavy or reactive loads (compressors, pumps) without stalling.
    • Ambient and Altitude Performance Better cold-start and high-altitude operation, often without the need for block heaters or special kits.
    • Fuel Flexibility Can run on biodiesel blends (B20–B100), waste oils, or low-grade distillates with minimal modifications.

    Analogy: Think of a diesel generator like a heavy-duty semi-truck engine versus a gasoline car engine. The truck’s engine is built thicker, runs slower under higher pressures, and hauls massive loads for hundreds of thousands of miles before overhaul. In contrast, a car engine, optimized for lighter loads and higher speeds, wouldn’t survive industrial duty.

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