Diesel generator monitoring is a hardware and software solution for fuel monitoring, monitoring of diesel generator operation parameters and engine diagnostics, receiving electrical data from alternator and remote genset control.
Smart solution for remote monitoring of diesel gensets allows ensuring uninterrupted operation of DG, reducing fuel and operation costs, optimizing maintenance schedule and preventing generator service outage, thus extending genset life cycle.
Smart Solution For Diesel Generator Monitoring Tasks
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Real-time data monitoring
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Remote engine diagnostics
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Remote control
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Fuel usage monitoring
Diesel Generator Monitoring Field Of Application
Remote diesel generator monitoring (also called generator telematics) is used for industrial and residential power generators, which are used as main, reserve or auxiliary energy source.
Users of the system :
- Owners and operators of generators. Remote supervision of operation and diesel generator management, genset fuel monitoring, getting data for accounting and predictive maintenance.
- Servicing companies, engaged in DG maintenance and repairs. Diagnostics of engine and alternator, operating time monitoring, maintenance scheduling, just-in-time servicing and replacement of consumables.
- Diesel generator manufacturers. Remote monitoring of genset operation, engine and alternator health monitoring and overall genset diagnostics, gathering failure statistics, planning adjustments to genset design.
Hardware for diesel generator monitoring
Main operating parameters are measured by additional and standard diesel generator sensors – fuel level, fuel flow and others, also received from Modbus RTU data converter.
Genset monitoring system includes the following measurement equipment (additional gensets sensors):
- fuel level sensors,
- fuel flow meters,
- I/o modules,
- Modbus RTU converters of data from a genset controller,
- CAN bus readers from engine J1939 data bus,
- telematics gateway.
All sensors and genset controller are connected into a single network over J1939/S6 interface or over-the-air wireless S7 Technology.
Telematics gateway (also called tracking unit or telematics unit) generates reports on generator operation using received parameters and sends information over the Internet (2G, 3G, LTE) to a web-based software platform. Also, diesel generator operation parameters can be checked locally on the screen of CAN display or genset controller screen.
Remote generator monitoring online
Genset engine and alternator operation parameters are measured and sent online in real time. Web-based genset monitoring and management platform shows users current values of parameters of each generator, group of generators or the whole genset fleet.
Genset monitoring and management platform allows a user to check genset operation for the selected period, generate analytical reports – on genset fuel consumption, generated power, engine workloads and so on. The platform is available 24/7 from PCs and smartphone with connection to the Internet.
UNUM Genset is a next-level solution for 24/7 monitoring and remote control of diesel generators. It combines smart telematics devices and modern software to improve efficiency, reduce fuel costs, ensure reliable operation across mixed fleets and environmental compliance.
Up to 400 operating parameters of a generator. In addition to sending data online, smart solution for remote monitoring of diesel gensets sends reports via email and SMS-notifications on detected events – engine start/stop, load on/off, parameter value drop, emergency stop, fuel theft and others.
Technoton solution for diesel generator monitoring is flexibly configured depending on type and model of a genset, installed DG controller and requirements of genset owner or operator to the parameters, which should be remotely monitored.
DG measured parameters and counters of operation
| Engine | Electric Generator |
| Instant fuel consumption; | Cos φ; |
| Average fuel consumption per hour; | Generator frequency; |
| Fuel volume in tank; | Generator voltage; |
| Fuel level in tank; | Generator voltage L1-N; |
| Engine RPM; | Generator voltage L2-N; |
| Coolant temperature; | Generator voltage L3-N; |
| Oil pressure; | Generator current; |
| Power network voltage; | Generator current L1; |
| Engine workload mode; | Generator current L2; |
| Battery voltage; | Generator current L3; |
| Battery mode – charging/ not charging; | Real power; |
| Total fuel used; | Real power L1; |
| Total engine operation hours; | Real power L2; |
| Engine operation hours for a period; | Real power L3; |
| Engine running time after the start; | Reactive power; |
| Total number of engine starts; | Total apparent power; |
| Number of failed engine starts; | UPS battery voltage; |
| Energy production per liter of fuel. | UPS remaining time; |
| Enclosure temperature; | |
| Status of enclosure/container cooling fan – working/not working; | |
| Status of enclosure/container blinds – opened/closed; | |
| Total energy produced. |
Event detected in DG operation
| Engine | Alternator |
| Maximum fuel consumption rate exceeded; | Emergency stop button pushed; |
| Too high RPM; | Too high voltage; |
| Low oil pressure; | Too low voltage; |
| High oil pressure; | Too high frequency; |
| Engine start failed; | Too low frequency; |
| Cold start; | Too high current; |
| Hot stop; | Too high power output; |
| No data in CAN bus; | Low Cos φ; |
| Low fuel level in tank; | Phase imbalance; |
| Fuel tank fill up; | Overload; |
| Fuel tank draining; | Enclosure/container door opened; |
| Engine start/stop; | Fire alarm. |
| Too high coolant temperature ; | |
| Too high oil temperature; | |
| Low UPS battery voltage. |
Genset automation and control
Technoton products for generator monitoring allow automation of some processes. For example, using data from fuel level sensor for diesel generator, DUT-E SAU fuel supply automation unit sends control signal to switching relay of a fuel pump, which ensures fuel pumping from storage fuel tank to main feed tank of a diesel genset. After fuel level in the main feed tank of the generator reaches a certain pre-defined value, DUT-E SAU fuel supply automation unit will send another control signal to switch off the pump. That kind of automation ensures uninterrupted operation of a diesel generator.
Also, the J1939 i/o module can turn off genset’s engine in case of detecting emergency value of an operation parameter, which can lead to generator breakdown – e.g. low oil pressure, too high coolant temperature and similiar.
