In factories and industrial workshops, equipment like air conditioners, cooling units, and pump stations require high-quality, stable power. Yet many companies face the same frustrating problem:
“We bought a high-capacity generator, but our workshop air conditioners and cooling units keep tripping or won’t start at all. Why is this happening?”
Don’t worry! Most of these issues stem from a few often overlooked technical details. Let’s break it down in simple terms so even beginners can understand.
Industrial Equipment Startup Draws Much More Power Than You Think
Many plant managers only look at the rated power on the equipment nameplate—for example, a cooling unit rated at 5 kW might seem fine with a 10 kW generator. However:
· Startup power can be 3–4 times the rated power
· Large pumps, compressors, and motors create a short but significant surge, which can trip the generator if it’s not designed to handle it
Industrial Example:
Last week, a food factory tried starting three cooling pumps simultaneously in the morning. The generator immediately tripped, causing the workshop temperature to rise, ice to melt, and production to halt. Engineers resolved the issue by staggering startup sequences and leaving sufficient power reserve.
Beginner Tip:
Avoid starting all equipment at the same time, or make sure the generator has extra power capacity to handle startup surges.
Phase and Voltage Mismatch Can Make Equipment “Refuse to Work”
Industrial machines often require stable single-phase or three-phase voltage. If the generator’s voltage phase doesn’t match the equipment, problems occur:
· Voltage fluctuates, making equipment unstable
· Air conditioners or cooling units stop and start intermittently
· One phase of the generator may overload
Industrial Example:
An electronics factory used a three-phase generator to power single-phase air conditioners. When one AC unit started, the control cabinet voltage dropped by half, causing frequent production line stoppages. After switching to a dual-voltage generator, the voltage stabilized and production ran smoothly without trips.
Beginner Solution:
Use a dual-voltage generator that automatically matches single-phase or three-phase loads, ensuring stable industrial equipment operation.
Slow Generator Response Can Cause Instant Shutdowns
Large compressors, cooling units, or other industrial equipment generate peak power during startup. If the generator’s Automatic Voltage Regulator (AVR) reacts slowly:
· Voltage dips briefly
· Equipment may stop instantly or trip protection
Industrial Example:
In a chemical plant, simultaneous startup of air conditioners and cooling pumps caused the old generator’s AVR to respond too slowly. Both pumps stopped, raw material temperatures rose, and production halted. After upgrading to a fast-response AVR generator, voltage stabilized immediately, and production efficiency improved significantly.
Beginner Tip:
Choose a generator with a fast-response AVR to ensure voltage stability during equipment startup, keeping production smooth.
Conclusion: Bigger Generators Don’t Always Solve Industrial Power Issues
Even beginners can remember these key points:
1. Leave enough startup power margin
2. Ensure voltage and phase match your equipment
3. Use a fast-response AVR
4. Consider the actual industrial environment
Following these guidelines ensures industrial equipment runs smoothly, eliminating generator-related disruptions.
Want Stable Operation for Your Industrial Equipment?
There are many dual-voltage, fast-response AVR generators available that can easily solve startup power surges and tripping issues, keeping your workshop running efficiently.
Contact us to select the right generator solution and keep your industrial equipment running reliably.
