Four Reasons of Prime 600kva Generator Failed to Start

When this is power failure, we most need diesel generators. But it cannot be 100% reliable, maybe there are some faults during the operation, such as startup failure. Recently, one of our clients ask us question about prime 600kva generator startup faults. So today this article is to explore fours reasons that cause generators to fail to start, and most importantly, how to reduce the risk of failure.

Normally, 600kva generator cannot operate normally, which means that monthly testing and maintenance schedules are essential to ensure that problems can occur with the operator’s knowledge. Let's take a look at the most common reasons why the generator can't start, and how to avoid this in the future.

1.Battery failure

Battery failure is one of the most common reasons why 600kva generator cannot start. This situation is usually caused by loose connections or sulfation (accumulation of lead sulfate crystals on the lead-acid battery plate). As the sulfate molecules in the electrolyte (battery acid) are discharged too deeply, fouling on the battery plate is caused, and the battery cannot provide sufficient current.

Battery failure may also be caused by the inoperable charger circuit breaker. It is usually because the charger itself is faulty, or it is caused by a tripped circuit breaker. At this time, the charger has been turned off and has not been turned on again. This situation usually occurs after repairs or maintenance have been carried out. After repair or maintenance, be sure to check the generator system again to ensure that the charger power circuit breaker is in the correct position.

Ultimately, battery failure may be due to dirt or looseness. The joints should be cleaned and tightened frequently to prevent potential failures. Dingbo recommends that you replace the battery every three years to reduce the risk of failure.

2.Low coolant level

If there is no coolant in the radiator, the engine will quickly overheat, causing mechanical failure and engine failure. Regularly check the liquid level of the coolant, and visually check for the presence of cooling puddles. The color of the refrigerant depends on the manufacturer, but it usually looks red.

The internal blockage of the radiator core will also cause the coolant level to be too low and the machine will shut down. When the generator is overloaded, when the engine reaches the optimal operating temperature, the thermostat is fully opened, which means that the radiator cannot allow proper flow through. In this way, the coolant will leak through the overflow pipe. When the engine cools down, the thermostat turns off, the liquid level drops, and the low cold liquid level to start the generator stops. This is because this will only happen when the generator runs to the optimal operating temperature under load conditions, so it is recommended that you test the generator with a high enough load to reach the temperature required to turn on the thermostat.

3. Cannot mix fuel

Generally speaking, the generator cannot be started due to the presence of fuel. The mixing of fuels can occur in many ways:

After the fuel is used up, the engine will absorb air, but there is no fuel.

The air inlet is blocked, which means there is no fuel but no air.

The fuel system may supply excess or insufficient fuel to the mixture. As a result, the inside of the engine cannot burn normally.

Eventually, impurities may be present in the fuel (such as water in a fuel tank), causing the fuel to fail to burn. This happens often because the fuel is stored in the fuel tank for a long time.

Reminder: As part of the daily service of the backup generator, the best way is to check the fuel to ensure that there will be no failure in the future.

4. There is no automatic mode for control

If your control panel displays the message "No automatic mode", this is caused by human error, usually because the main control switch is in the shutdown/reset position. If the generator is in this position, the generator may not start in the event of a power failure.

Check the generator control panel frequently to make sure that the information is not displayed "automatically". Many other faults will cause the generator on the control panel to fail to start. I hope this article can provide you with some reference opinions and explain the common reasons why the generator can't start. Remember that generators are very similar to cars and require regular maintenance. Toppower provides you with a series of maintenance services for diesel generators to meet your needs.