Diesel generator maintenance with IoT: remote monitoring, diagnostics, and management

Households and businesses purchase diesel generators for uninterrupted operation and high work output despite possible blackouts. The more intensively each diesel generator works, the sooner maintenance issues will arise.

By then, people can enjoy these super-efficient energy sources due to:

• High durability.
• Relatively low maintenance requirements when operated in normal conditions.
• Lower prices and higher accessibility of diesel when compared to petrol.

Although it’s highly durable and efficient, a diesel generator may become a fuel drainer if left unattended.

What is the most cost- and fuel-efficient generator?

The one properly maintained. By controlling the factors below, a company can make any generator cost- and fuel-efficient.

Fuel types

The type of diesel used in generators goes a long way toward the fuel consumption rate. Using a high-quality fuel like Super Diesel gives the best results, while fueling up some no-name diesel may lead to higher fuel consumption.

Overusing and underusing generators

Overusing and underusing generators raise fuel consumption.

• During a blackout, the generator powers more appliances than usually, which overloads it and increases fuel consumption.
• Similarly, using less than 50% of the generator output can cause high fuel consumption. It happens because the generator engine needs more time to reach its maximum operating temperature. Thus, the generator will struggle to work, resulting in more fuel usage.

Maintaining the correct coolant temperature

Diesel generators use water as a coolant for optimal operation. The ideal water temperature should be between 45 to 65 ℃. If this criterion is not met, it leads to more fuel generation due to incomplete combustion and inefficient performance.

Carbon Deposits

Carbon deposits settle out during the combustion process. The heated diesel releases a carbon polymer that smothers the injector, valve, and piston top. It is one of the reasons why diesel generators emit black smoke after some time. If you don’t remove these deposits in time, it will cause more fuel consumption.

Engine running time

Generators’ engine running time also affects fuel consumption. The more time the generator runs, the more fuel it consumes and the earlier it will demand repair. Therefore, minimizing the use of generators and sometimes switching to solar power or other alternative sources is a long-term measure to reduce fuel consumption and prevent breakdowns.

Remote diesel management systems can track and help maintain all these parameters.

Diesel generator maintenance options

Although diesel-powered generators are a very efficient brand of uninterrupted energy supply, managing and maintaining them manually is a very daunting task that comprises:

• Routine inspections;
• Diesel level checks;
• Technical audits;
• Diagnostics after electricity outages and faults.

To cope with these tasks, one can employ professional repairmen or use specialized diesel generator monitoring services. Both the options cost a fortune.

The failure to maintain a generator properly may result in an equipment breakdown, which will cost you twice more than the original purchase price. However, you can reduce these drastic maintenance costs by using a few sensors and an IoT platform by KLOUDIP.

HAZER is a secure, reliable, and user-friendly IoT platform designed to manage buildings, vehicles, and machinery, like diesel generators, remotely via sensors. It’s a cost-efficient alternative to specialized generator monitoring platforms, industrial boards, and on-site maintenance teams. 

Let’s see how it works. 

How to service a diesel generator remotely: HAZER method

KLOUDIP connects diesel generators to the IoT software for remote management in three simple steps. 

1. Install IoT devices to monitor various diesel generator parameters – temperature and fuel level sensors, RPM counters – or connect generators to HAZER via OEM hardware.
2. Install IoT gateways to transmit data at long ranges. These gateways can send you the generator performance data, even if you work remotely from home or another country.
3. Pre-configure a generator monitoring dashboard, notifications, and Smart Rules in the HAZER IoT platform.

On the dashboard, you see all the generator parameters as colored widgets. These widgets show sensor values and change colors if something goes wrong (for example, if diesel is running out). You can create a separate dashboard for each fuel generator. 

Additionally, the system alerts responsible persons via SMS, emails, pop-up notifications, or messengers in real-time. 

If there’s something wrong with a generator, but no one is near, the operator can manage it remotely via commands or automatically via Smart Rules. 

In the latter case, an operator outlines how HAZER should behave in this or that situation in advance. When something happens, HAZER acts according to the established rules. For example, if the system detects a critical overload, it can turn the generator off to prevent the breakdown.  

By managing the generator system with the remote software, a company performs on top of its efficiency and knows the status of each generator every second, including:

• Fuel levels;
• Water cooling temperatures;
• Engine running times, load, and a dozen more parameters.

Get your management system from KLOUDIP or learn more about the HAZER IoT platform from the video below.