Telecom diesel generator sets are specifically designed to ensure continuous and stable power supply to critical communications facilities such as base stations, core equipment rooms, and data centers in the event of a utility power failure. Their core mission is to quickly, automatically, and reliably start and assume all or most of the load in the event of a utility power outage, ensuring uninterrupted operation of communications equipment and network connectivity.
Core Requirements and Features (Different from General-Purpose Generators)
1. High Reliability:
Downtime in telecommunications facilities is costly, so generator sets must have an extremely high MTBF (Mean Time Between Failures).
Key components (engine, generator, controller) are mature products from internationally renowned brands.
Redundant Design: Redundancy is incorporated into critical systems (such as starting batteries and control system power supply).
Strict factory testing: 100% load testing (typically over 4 hours) simulates various operating conditions.
2. Fast Startup and Switchover:
Short cold start time: At room temperature (>5°C), the time from issuing the start command to the equipment operating under load is typically 10 to 15 seconds. Fast ATS Switching Speed: The matching Automatic Transfer Switch (ATS) typically switches from off to on in under 10 seconds, meeting the stringent power interruption requirements of communications equipment (e.g., IT equipment requires <20ms, but base station equipment can typically withstand switching times of several seconds).
The engine features an optional pre-lubrication system to reduce wear during cold starts.
3. Excellent Electrical Performance:
Voltage and Frequency Stability: Steady-state voltage regulation range is within ±1%, transient voltage regulation range is within ±20% (recovery time less than 1 second); steady-state frequency regulation range is within ±1%, transient frequency regulation range is within ±10% (recovery time less than 3 seconds). This meets G3 (ISO 8528-5) standards or higher.
Low Harmonic Distortion: THD (Total Harmonic Distortion) is <5% (for non-linear loads <30%), preferably <3%, to avoid interference with precision communications equipment. Ability to withstand non-linear loads: Modern communications equipment (such as switching power supplies and servers) often have non-linear loads (high harmonic currents). Therefore, the unit must have sufficient peak current handling capacity (typically requiring a crest factor ≥ 1.5:1) and the ability to withstand 100% non-linear loads.
4. High Efficiency and Low Fuel Consumption:
High operating efficiency at typical load rates (e.g., 70-80%).
Low fuel consumption (g/kWh) reduces long-term operating costs.
5. Wide Environmental Adaptability:
Temperature Range: Standard models typically operate from -15°C to +40°C (ambient temperature, not coolant temperature). Cold regions require a jacket water heater, fuel heater, and high-cold lubricant; hot regions require enhanced cooling systems.
Altitude: Standard models are suitable for altitudes below 1000 meters. Above 1000 meters, power adjustments are required (typically, power decreases by approximately 3-4% for every 300 meters of altitude), or a high-altitude engine should be selected. Dust and Moisture Resistance: The chassis has an IP23 or higher protection rating, preventing the intrusion of dust and water droplets. Special anti-corrosion treatment is required in humid and salt-spray areas.
6. Low-Noise Design:
Communication base stations are often built in residential areas or on rooftops and must comply with local environmental noise regulations (typically, noise levels should be below 75-85 decibels (dBA) at a distance of 1 meter from the equipment).
Utilize high-efficiency silencers, silent enclosures (with sound-absorbing materials), and vibration-damping mounts.
7. Automation and Remote Monitoring System:
The intelligent controller is a key component of the system, providing automatic start and stop functions, switching control, and the ability to monitor multiple parameters, including voltage, current, frequency, power, water temperature, oil pressure, speed, battery voltage, and operating hours. It also features fault alarms and protection mechanisms to address issues such as overspeed, underspeed, low oil pressure, high water temperature, overcurrent, and short circuits, as well as self-diagnostic capabilities. Remote Monitoring Interface: Standard RS485/RS232 and Modbus RTU/TCP protocol interfaces enable easy integration into the site's dynamic monitoring system (FSU). Optional GPRS/4G/5G wireless modules, SNMP cards, or network ports enable remote status monitoring, start/stop control, alarm push notifications, and historical data query.
8. Long-Term Standby and Low Maintenance:
The fuel tank capacity is typically designed to provide 8-24 hours of full-load operation (depending on the site's criticality and accessibility).
The design incorporates reliability considerations for long-term standby operation (e.g., battery float charge management and anti-condensation heating).
Long maintenance intervals (e.g., 250 hours for the initial oil change and 500 hours for subsequent oil changes) reduce O&M costs.
Easy Maintenance: A well-designed human-machine interface ensures easily accessible maintenance points.
9. Compact design facilitates transportation and installation.
Particularly for distributed base stations, small size and light weight are crucial (often using a 4- or 6-cylinder engine). The all-in-one design (with the base oil tank, control cabinet, ATS, etc. integrated within the silent enclosure) allows for simple and quick on-site wiring.
Key Selection Considerations
1. Load Capacity Calculation:
Accurately calculate the site's maximum continuous load power (kW) and maximum starting surge power (KVA) (especially the starting current of the air conditioner compressor).
Allow a 10-25% power margin for future expansion needs.
The load type (linear/non-linear) determines the required unit capacity and performance.
Unit Rated Power Selection Criteria: Maximum continuous load ≤ unit rated power (rated power PRP) × power factor (0.8). Starting surge is instantaneous; as long as the unit has sufficient peak load capacity, it will be sufficient.
2. Installation Environment:
Space Constraints: Equipment room area, door opening dimensions, and load bearing capacity.
Ventilation and Heat Dissipation: The design of the air inlet and exhaust ducts is crucial and must meet the unit's heat dissipation requirements and comply with local fire regulations.
Noise Limits: Determine the silent enclosure rating and possible additional noise reduction measures. Altitude and climate: Affect power adjustments and special configuration requirements (freeze protection, cooling).
Foundation Requirements: A level, solid concrete foundation with vibration reduction measures.
3. Fuel Supply System:
Base tank: Most commonly used, integrated under the unit base, with limited capacity.
External tank: Larger capacity, requires separate installation. Note that the tank height must meet the engine suction requirements and typically requires a fuel pump.
Fuel supply piping: Use standard materials (usually copper or stainless steel), with a specified diameter and slope to avoid air lock.
Fuel Management: Regularly test oil quality (for water, impurities, and microorganisms), and consider adding stabilizers.
4. ATS Configuration:
Switching Method: Closed switching (Break-Before-Make) is most commonly used.
Number of Poles: 3P (three-phase) or 4P (three-phase + neutral).
Rated Current: Greater than the unit's maximum output current and the mains current. Control Logic: Works closely with the unit controller to detect utility power anomalies, issue start commands, provide status feedback, and execute switchovers.
Mechanical/electrical interlocks: Prevent simultaneous application of utility power and generator power.
5. Monitoring and Communication:
Define the indicators to be monitored and the alarm thresholds.
Confirm interface methods and protocol compatibility with the existing power supply monitoring system (FSU).
Is remote start/stop functionality required? Is wireless transmission required?
6. Brand and Service:
Choose a brand with extensive experience and a good reputation in the telecommunications industry.
A localized service network is crucial: ensure fast response times (e.g., on-site arrival within 4/8 hours), sufficient spare parts availability, and experienced technicians. Prioritize maintenance contract options offered by the supplier.
Installation and Maintenance Key Points
1. Installation:
Strictly follow the manufacturer's installation manual.
Have professional personnel perform foundation construction, equipment transport and placement, and oil and electrical piping connections.
Ensure adequate ventilation and that exhaust backpressure meets requirements (exhaust ducts must be insulated and slope downward).
The grounding system must be stable and comply with relevant standards. All electrical connections must be secure and clearly labeled.
After installation, perform comprehensive testing: no-load operation, load testing (gradually increasing to full load), ATS switching simulation test, alarm and protection function testing, and monitoring signal upload testing.
2. Maintenance:
Develop a preventive maintenance (PPM) plan: Strictly follow the manufacturer's recommended maintenance schedule and content (daily, weekly, monthly, quarterly, semi-annual, and annual inspections). Key Maintenance Items:
Oil and filter replacement
Fuel filter replacement
Air filter cleaning and replacement
Coolant inspection, replenishment, or replacement (check freezing point and corrosion resistance)
Cooling system cleaning (radiator, intercooler)
Starter battery inspection (voltage, fluid level, specific gravity), terminals clean and tighten, and regular replacement (usually every 2-3 years)
Belt tension inspection and adjustment
Exhaust system inspection (leakage, water accumulation)
Fastener inspection
Control circuit inspection
Simulated utility power interruption test (run regularly under load, at least once a month, for at least 30 minutes each time to lubricate the engine, burn off carbon deposits, and verify system reliability).
Records: Keep detailed records of each maintenance session, any problems found, any parts replaced, and operating hours.
Fuel Management: Use clean diesel that meets standards, and regularly drain the fuel tank to remove moisture and impurities. Consider using fuel additives.
Professional Maintenance Personnel: Maintenance should be performed by trained and qualified personnel.
Important Notice: Safety First: Always follow all safety procedures when operating and maintaining the unit. High temperatures, rotating parts, flammable materials, and electrical hazards all require vigilance.
In-depth communication with suppliers: Providing as detailed site information and requirements as possible, and working closely with an experienced telecom generator set supplier are key to project success.
Lifecycle cost: Purchase price is only part of the total cost; factors such as reliability, fuel efficiency, maintenance costs, and service support must also be considered.
Conclusion
Telecom diesel generator sets are the lifeline of the secure operation of the communications network. Selecting the right unit and professionally installing and maintaining it are essential to ensure its critical performance at critical moments. A comprehensive evaluation and decision-making process must be conducted based on multiple factors, including reliability, performance, environmental adaptability, automation level, service quality, and cost.
