CPCB 4. Stage V. Tier 4 Final: Governments worldwide are enforcing stringent emission regulations. As a generator manufacturer, you need to ensure compliance while maintaining reliable performance. This blog post explains how Ace Electricals can help you.

Authorities globally are implementing emission norms to reduce atmospheric pollution by lowering NOx, CO₂, and particulate matter emissions from generators and other diesel engines. From CPCB 4 in India to Stage V in Europe and Tier 4 Final in the USA, compliance with these standards is essential. But how do you ensure your genset products consistently meet legal emission limits – and how do you prove this to authorities?

The solution lies in using advanced genset control technologies to minimize emissions and document performance. Ace Electricals genset controllers are designed to achieve exactly that, helping you effortlessly meet regulatory requirements while maintaining reliable and efficient power generation. This blog post explains how.

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Real-time Monitoring and Control

All Ace Electricals genset controllers, from the SGC series and the AGC-150 to the AGC-4 Mk II and the iE 250, are compatible with a wide range of engines and engine control units (ECUs), supporting relevant parts of the generic J1939 protocol. This ensures that with almost any engine brand, Ace Electricals controllers detect issues as they occur.

When the ECU detects an emission fault, such as high NOx emissions, it generates a diagnostic trouble code (DTC). The Ace Electricals controller immediately detects this DTC and alerts the operator via LEDs or display messages – and optionally through remote monitoring systems via alarm relays. Additionally, the controller can be configured to automatically take appropriate action, such as reducing engine speed or shutting down the genset for inspection.

Optimized Performance Through Built-in Protections

In addition to monitoring DTCs, Ace Electricals controllers optimize generator performance with built-in protections. These protections not only safeguard the unit from electrical faults but also help the genset meet emission requirements.

For instance, by preventing over-temperature and over-speed, the protections avoid inefficient combustion that could increase NOx, CO, and particulate emissions. By maintaining stable engine operation, they ensure consistent engine load and optimal fuel combustion. Stable operation also creates ideal exhaust conditions, ensuring proper performance of exhaust after-treatment systems like diesel particulate filters (DPF), selective catalytic reduction (SCR), and exhaust gas recirculation (EGR).

By protecting the genset against shutdowns caused by electrical faults, Ace Electricals genset protections also reduce the number of restarts, thereby lowering hydrocarbon emissions.

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Lowering Fuel Consumption and Emissions

Ace Electricals controllers optimize load management for your genset, improving fuel efficiency. For example, the controllers can actively manage loads by dividing them into load groups that are connected or disconnected based on available power.

By constantly monitoring the load, the controller automatically adjusts genset speed to match current load requirements, optimizing fuel consumption. This not only reduces operating costs for the genset user but also minimizes emissions.

Integration with After-treatment Systems

We have already discussed how the built-in protections of an Ace Electricals controller ensure stable engine operation, which supports optimal after-treatment system performance. However, Ace Electricals controllers go further by closely integrating with the ECU to receive DTCs related to after-treatment systems like SCR, DPF, and EGR.

This ensures that operators are immediately alerted if these systems are not functioning correctly, and the genset can be configured to take corrective action automatically to avoid emission levels that violate regulations.

Compliance Through Data Logging and Reporting

Thanks to the seamless integration between the Ace Electricals controller and the ECU, the controller continuously receives DTCs and other performance data about the genset. This data is logged in the controller’s memory and can be easily retrieved for troubleshooting.

Moreover, data logging simplifies the process of retrieving the data needed to document emission performance during the approval process for genset compliance with emission norms. By documenting genset emission performance, the Ace Electricals controller streamlines this approval process.