Emergency Generator Calculation
Emergency Generator Calculation
Reliable automatic switchover during power outages.
An ATS (Automatic Transfer Switch) is a smart and reliable switching solution that ensures your installation is automatically supplied with power when combined with an emergency generator. The ATS is built into a cabinet and automatically switches between the public electrical grid and an emergency generator.
How does it work?
- Normal operation: the installation is powered from the electrical grid.
- Power outage: a mains voltage interruption is detected and a start signal is sent to the emergency generator.
- Switchover: once the generator is running, the ATS automatically switches over to this emergency power supply.
- Power restoration: when the electrical grid is stable again, the ATS switches back and safely shuts down the generator.
Benefits of an ATS
- Uninterrupted business continuity – critical processes keep running.
- Fully automatic and autonomous – no manual intervention required.
- Safe and reliable – compliant with international standards and industry requirements.
- Compact cabinet design – turnkey solution, easy to install and maintain.
An ATS in enclosure is available in various power ratings and configurations. The standard power rating is determined by the generator set's power output. Naturally, custom power ratings are also available.
Dimensions and schematics for these reversing switches are available upon request.
The switchboard for grid synchronization is a robust and reliable solution that enables the generator set to synchronize with the MAINS. The cabinet contains all necessary components including a MAINS and GEN switch so the installation can operate safely and efficiently during parallel operation or grid support.
The control panel is designed for durable and maintenance-friendly operation and features a compact, well-organized design with all necessary connections and protection systems. The panel can be easily integrated into your installation and meets international standards and industry requirements.
Key features:
- Robust construction, suitable for both indoor installation
- Compact and well-organized component layout
- Adaptable to various power ratings and grid configurations
- Easy installation and accessible maintenance
This switchgear cabinet serves as the physical heart of the grid parallel connection, while the engine set's control and synchronization are handled through the ComAp control system. Schematics and dimensions are available upon request and can be tailored to meet specific project requirements.
This switchgear cabinet is required when the machine needs to synchronize with the GRID. To complete the installation, a ComAp control computer is needed to operate the switches.
Benefits of extended parallel operation
- Uninterrupted power supply with seamless transfer when mains power is restored
- Optimal power control and load support capability
- Suitable for critical and continuous processes
- High flexibility in operations and energy management
- Easy to integrate into existing installations
- Capability to perform load testing
The enclosures from Abato Motoren are engineered for long-term, trouble-free operation in outdoor applications. The robust frame is fully galvanized, providing excellent resistance to weather conditions and mechanical stress. The enclosure also features rain strips that ensure precipitation is effectively channeled away, keeping internal components optimally protected.
A key feature of our enclosures is how they are manufactured. All sheet metal parts and components are individually coated before assembly. This prevents vulnerable, uncoated seams or overlapping sections where rust can develop. Additionally, the panels are nailed rather than screwed, which eliminates stress that could damage the coating. This contributes to the longevity, stability and corrosion resistance of the structure.
The finish meets corrosion class C3 standards, making it suitable for industrial and urban environments. The coating thickness is over 200 µm, which significantly exceeds standard market practices and provides enhanced protection against wear and corrosion. The entire process takes place in a fully automated paint system, ensuring consistent quality and coating thickness.
With these high-quality enclosures, Abato Motoren provides a durable, low-maintenance and reliably protected housing for your emergency generator. This ensures you have an installation that not only meets technical requirements, but also withstands all daily and extreme weather conditions for years to come.
It's also possible to supply the emergency generators in a container. Contact us to discuss the options!
Linz Electric S.p.A. is an internationally recognized manufacturer of high-quality alternators, established in 2002 and part of the Pedrollo Group. With decades of experience in design, production and innovation, Linz Electric delivers a complete range of Made in Italy alternators for both industrial applications and emergency power systems. From compact units to powerful alternators for Continuous and Stand-By applications. The alternators are also used in the available trailer-mounted generator sets.
Linz Electric products are developed using advanced manufacturing technologies and high-quality materials, delivering exceptional electrical performance, mechanical durability and reliability across diverse operating conditions. Linz alternators are engineered for optimal use in emergency power systems, ensuring dependable power availability, enhanced performance and extended service life for your installation.
Choose Linz Electric as a premium option for your configuration and benefit from a component renowned for its quality, performance and global support.
ABATO develops prefab flue gas exhaust system
This prefabricated flue gas exhaust pipe has been developed and manufactured in-house by Abato Motoren B.V. All required bolts and gaskets are included.
- RVS flexibel en pakkingen.
- Stalen buis, gepoedercoat, 90° bocht, lengte 2 meter.
- Anti-inregenklep Raincap™.
- Bevestigingsbeugels, 2 stuks.
- Draadeind, 2 stuks, 1 meter.
- Bevestigingsstrips met opgelaste M10 moer, 2 stuks.
- Muurbeugel
- 12x M10 flensmoer
- 12x M10 flensbout
- 24x M10 sluitring
- Glasband
- RVS draad
The anti-condensation heating system has been designed to prevent moisture buildup in your emergency generator’s alternator. Condensation can cause corrosion, short circuits, and reduced performance, particularly during extended periods of inactivity or in humid environments. By using this heating system, the alternator is kept dry and ready for operation, significantly enhancing the reliability of the generator set.
The system operates through a combination of wrap-around heating element, indicator light, and mounting clips. The wrap-around heating element is secured tightly against the alternator surface and provides consistent, even heating. The indicator light provides visual confirmation that the system is active, allowing you to immediately verify that the anti-condensation function is working.
By maintaining the correct temperature, the unit is protected against corrosion and moisture-related failures, enabling it to start reliably immediately during a power outage. This extends the alternator’s service life, reduces maintenance costs, and contributes to the continuity of critical power supply.
All in all, this is an addition to your installation that is definitely recommended when you decide to position the generator set outdoors.
The galvanized air vents are designed for efficient air intake and exhaust through the unit’s exterior casing. Proper airflow is essential for reliable cooling of the engine and optimal system performance.
When the radiator cannot be positioned directly against the grille, an air duct is used to properly guide the air intake and exhaust.
Damper registers can also be mounted against the air louvers. These dampers can automatically regulate the airflow. When at standstill, the dampers remain closed to prevent unwanted drafts and heat loss. In case of a power failure or start signal from the generator set, the dampers open automatically, immediately restoring airflow and allowing the generator set to cool safely.
Air vents can be fitted with integrated baffle silencers that provide effective noise reduction during operation. However, this may affect the required size of the air vents. Please inquire about the available options.
The above configuration contributes to reliable operation, quiet installation, and energy-efficient air circulation around the emergency generator set.
The galvanized air vents are designed for efficient air intake and exhaust through the unit’s exterior casing. Proper airflow is essential for reliable cooling of the engine and optimal system performance.
When the radiator cannot be positioned directly against the grille, an air duct is used to properly guide the air intake and exhaust.
Damper registers can also be mounted against the air louvers. These dampers can automatically regulate the airflow. When at standstill, the dampers remain closed to prevent unwanted drafts and heat loss. In case of a power failure or start signal from the generator set, the dampers open automatically, immediately restoring airflow and allowing the generator set to cool safely.
Air vents can be fitted with integrated baffle silencers that provide effective noise reduction during operation. However, this may affect the required size of the air vents. Please inquire about the available options.
The above configuration contributes to reliable operation, quiet installation, and energy-efficient air circulation around the emergency generator set.
The galvanized air vents are designed for efficient air intake and exhaust through the unit’s exterior casing. Proper airflow is essential for reliable cooling of the engine and optimal system performance.
When the radiator cannot be positioned directly against the grille, an air duct is used to properly guide the air intake and exhaust.
Damper registers can also be mounted against the air louvers. These dampers can automatically regulate the airflow. When at standstill, the dampers remain closed to prevent unwanted drafts and heat loss. In case of a power failure or start signal from the generator set, the dampers open automatically, immediately restoring airflow and allowing the generator set to cool safely.
Air vents can be fitted with integrated baffle silencers that provide effective noise reduction during operation. However, this may affect the required size of the air vents. Please inquire about the available options.
The above configuration contributes to reliable operation, quiet installation, and energy-efficient air circulation around the emergency generator set.
The galvanized air vents are designed for efficient air intake and exhaust through the unit’s exterior casing. Proper airflow is essential for reliable cooling of the engine and optimal system performance.
When the radiator cannot be positioned directly against the grille, an air duct is used to properly guide the air intake and exhaust.
Damper registers can also be mounted against the air louvers. These dampers can automatically regulate the airflow. When at standstill, the dampers remain closed to prevent unwanted drafts and heat loss. In case of a power failure or start signal from the generator set, the dampers open automatically, immediately restoring airflow and allowing the generator set to cool safely.
Air vents can be fitted with integrated baffle silencers that provide effective noise reduction during operation. However, this may affect the required size of the air vents. Please inquire about the available options.
The above configuration contributes to reliable operation, quiet installation, and energy-efficient air circulation around the emergency generator set.
The ComAp GSM module is a plug-in communication module for ComAp controllers that provides reliable 4G connectivity. The module enables remote monitoring, control and location tracking of generator sets through the ComAp WebSupervisor platform or via direct communication with the controller.
The module supports 4G LTE connections with automatic fallback to 3G and 2G, ensuring reliable data communication even in areas with limited coverage.
The module is designed for seamless integration into existing ComAp systems and connects directly to the controller. This eliminates the need for an external modem or gateway. The module is ideally suited for applications requiring remote monitoring, service optimization, and security of mobile or stationary generator sets.
The module can be integrated by Abato Motoren into the control computer that is offered.
However, the user must subscribe to a mobile plan and insert a SIM card into the module.
The ComAp Ethernet module is a plug-in communication module that connects your generator set’s controller to a network via a wired Ethernet connection. The module enables remote monitoring and control of your generator set’s control computer by providing access to engine signals, generator and load values, mains voltage values, and alarm or historical data.
Key technical features:
- Ethernet port for wired internet connection, utilizing existing network infrastructure.
- Support for ComAp's AirGate connection system, enabling the controller to securely access the internet without requiring a static or public IP address, and autonomously navigate through firewalls/VPNs.
- Support for protocols such as Modbus and SNMP for integration with building management systems (BMS) or SCADA installations.
This module is ideally suited for permanent installations where a stable network connection is available and where real-time data exchange and integration with larger management platforms is required. The module enhances the reliability of your remote monitoring, reduces response time during failures, and supports efficient maintenance of the installation.
The user must install appropriate cabling for this purpose.
The coolant heater option is a compact and reliable engine pre-heater that keeps diesel and gas engines at operating temperature. This pre-heater is used with stationary generating sets and is ideal for applications where an immediate start and dependable operation of the emergency generator is required.
The system continuously heats the coolant and actively circulates it through the engine. This keeps
the engine at the correct operating temperature, resulting in faster starts, reduced wear and less strain on the battery and starter motor. The coolant heater is renowned for its energy-efficient operation and long service life, contributing to greater overall reliability of the installation.
By fitting an engine pre-heater, the reliability and availability
of the generator set are significantly improved, making it an essential component of any professional emergency power system.
The heating output of the coolant heater is selected based on the generator set's power rating. Two configurations are available: a static version or a version with an integrated circulation pump. The circulation pump variant actively circulates the heated coolant throughout the engine, ensuring an even temperature distribution and reliable starting performance.
The coolant heater option is a compact and reliable engine pre-heater that keeps diesel and gas engines at operating temperature. This pre-heater is used with stationary generating sets and is ideal for applications where an immediate start and dependable operation of the emergency generator is required.
The system continuously heats the coolant and actively circulates it through the engine. This keeps
the engine at the correct operating temperature, resulting in faster starts, reduced wear and less strain on the battery and starter motor. The coolant heater is renowned for its energy-efficient operation and long service life, contributing to greater overall reliability of the installation.
By fitting an engine pre-heater, the reliability and availability
of the generator set are significantly improved, making it an essential component of any professional emergency power system.
The heating output of the coolant heater is selected based on the generator set's power rating. Two configurations are available: a static version or a version with an integrated circulation pump. The circulation pump variant actively circulates the heated coolant throughout the engine, ensuring an even temperature distribution and reliable starting performance.
The following work, inspections, measurements and replacements are performed during the 1st maintenance service:
- Visual inspection of the complete unit; checking the following points: cleanliness, oil leaks, diesel leaks, coolant leaks, condition of vibration dampers, mountings, signaling and safety equipment, batteries
- Reading out generator control history
- Control software update required for steering system
- Check engine oil level
- Check voltage and frequency during unloaded test run. (including pressures, temperatures and safety systems)
- Control of voltage, frequency and power during loaded test run (by arrangement only) (incl. pressures, temperatures and safety systems)
- Inspection of installation layout in the space regarding exhaust gas discharge and adequate air supply and extraction
- Check outgoing relay operation
- Check batteries, battery terminals and wiring, test batteries electronically and under load
- Check battery charging system for proper operation, charge current distribution and readjust if necessary
- Check and replace oil, water, and fuel filters as needed (per manufacturer specifications)
- Replace engine oil (if necessary)
- Check and clean air filter (if necessary)
- Check hoses and hose connections for leaks and hardening
- Check coolant level and antifreeze protection
- Check cooling water heating system operation
- Check crankcase ventilation
- Check crankcase heating
- Check belt tension and condition
- End-to-end alarm testing
- Check switching unit fuses
- Diesel quality inspection (visual inspection)
- Diesel tank visual inspection
- Check fuel gauge
- Check feed pump
- Tighten external bolts and nuts as needed
- Inspect exhaust pipe for damage and potential leaks
- Check for presence of spare fuses
- Equipped with on-site logbook recording
- Training on operation for on-site personnel
- After completion, return generator to 'auto' mode
- Work report with documentation of performed activities, replaced materials and observed anomalies
- When irregularities are identified, additional customer contact and consultation/proposal
During commissioning, the generator is started up for the first time and a power outage is simulated. The generator is thus tested and it is verified that the engine temperature does not rise and the generator can properly take over the load for which it is intended. At the same time, instructions on operation can be provided. A skilled, competent installer can handle the commissioning.
During commissioning, all critical parameters are monitored, including engine temperature, oil pressure, voltage, frequency, and the operation of safety systems. This ensures that the generator set operates reliably within its technical specifications and can be safely deployed for its intended application.
Beyond the technical testing, commissioning also provides an opportunity for hands-on training on operation and the fundamental principles of daily use. This gives the end user insight into how the system works, control panel notifications, and procedures for troubleshooting or maintenance.
Commissioning is carried out by a qualified and experienced technician who possesses the necessary expertise in engines, electrical engineering, and control systems. This ensures professional delivery and reliable startup of your installation. When you wish to commission a generator set that can synchronize with the mains grid, different rates may apply.
When you want to commission a generator that can synchronize with the GRID, different rates may apply.
Cost calculation
Calculate emergency generator price
Select the desired kVA rating and the calculator will compute the corresponding prices. You can then check the various options to get a clear price indication.
In step 1 you choose the power rating.
In step 2 you make additional choices for options/configurations, delivery, and optionally select maintenance packages alongside the basic setup.
In step 3 you review the complete overview to get a cost estimate.
