Help! – our generator doesn’t work

This job started out as a fairly routine call to our Sydney office, the customer indicated they were having issues with their standby diesel generator not operating correctly. They had a weekend test scheduled and wanted us along to see how the system was performing and advise what could be done to improve its reliability.

One quick look at the generator controller and anyone could tell this wasn’t going to be a simple fix but apparently those that came before us were not so quick to put forward a solution. The test run was completed which allowed us to see the full operation (and failure) of the generator, controller, and transfer switch. Without a doubt the only fix for this was a re-wire of the control system.

We proposed keeping the existing control cubicle to keep the project cost down, and quoted to install the Deep Sea 7320 auto mains failure generator controller.

Deep Sea 7320

The first step was carefully start disconnecting and documenting the existing control system. With no drawings, wire numbering, or documentation available we had to determine the function of each and every wire in the cubicle. Drawing a wiring diagram as we went (this will be the subject of a later post) we managed to identify all the cabling and could begin the clean up and design process for the new controller.

Back of Deep Sea Controller

As the new controller was installed all the interconnecting cabling was renewed and clearly labelled to match the wiring diagram that would be provided to the client at the end of the project.

After image of Diesel Generator Controller

While still a little squeezy the improvement over what we faced originally is obvious. Now the customer has a reliable generator control system complete with instructions, wiring diagrams and clearly labelled cabling. Another happy customer for Power Protect.