Aurora Generators

About Aurora Generators

Join the team at Aurora Generators, North American trusted manufacturer of premium diesel-powered generators, as we dive into everything you need to know about backup power. From off-grid living and emergency preparedness to generator maintenance, installation tips, and industry trends — we cover it all. Whether you're a homeowner, contractor, or power enthusiast, our expert insights and real-world stories will help you make informed decisions and stay powered up when it matters most. Subscribe and discover how reliable diesel power can change the way you think about energy independence.

Publisher

Aurora Generators

Category

education · news · technology

Language

en

Explicit

No

First episode

2 Jun 2025

Latest episode

22 Jun 2025

Latest episodes

10 episodes in the feed.

1. 

   22 Jun 2025

   Diesel Engine Wet Stacking: Causes, Consequences & Prevention

   Diesel Engine Wet Stacking: Causes, Consequences, and Prevention Introduction Diesel-powered generators are renowned for their reliability and fuel efficiency, outperforming gasoline, propane, and natural gas units in both longevity and operating costs. However, to deliver on that promise, they must be run under sufficient load. Operating a diesel generator “light” or idling for long periods leads to a phenomenon called wet stacking, sometimes nicknamed “engine slobber.” Left unchecked, wet stacking degrades performance, increases maintenance costs, and can even void the manufacturer’s warranty. In this post, you’ll learn: What wet stacking is, and why only diesel engines experience it The root causes, from low-load operation to fuel-system faults How wet stacking damages cylinders, rings, injectors, oil, and exhaust systems Practical prevention strategies, including correct sizing and load-banking Early-stage remediation techniques you can perform yourself When to call in certified Perkins or Caterpillar technicians Warranty implications and why prevention is the best protection What Is Wet Stacking? Definition:Wet stacking occurs when unburned fuel and heavy hydrocarbons accumulate in the exhaust system and cylinder walls of a diesel engine. Rather than fully combusting, extra fuel condenses into oily black sludge (“wet stack”) that drips from the exhaust or turbocharger housing. How to Recognize It: Visible Signs: Dark, oily deposits around the exhaust outlet or downpipe; black residue on nearby surfaces. Audible/Sensory Cues: A strong diesel smell after shutdown; popping or back-firing at startup. Engine Behaviour: Blue-gray smoke on acceleration; lower exhaust temperatures at idle. Primary Causes Low-Load Operation: Running below 30–60% of rated capacity prevents cylinders from reaching optimal combustion temperature. Oversized Units: Generators sized for peak demand but seldom loaded will chronically under-utilize capacity. Combustion Pressure & Sealing Issues: Low cylinder temperatures cause ring glazing, which reduces seal effectiveness and worsens incomplete combustion. Fuel-System Faults: Over-fueling: injection timing or metering set too rich. Worn or mis-set injectors: leaks or poor spray patterns. Incorrect air–fuel ratio: blocked air filters or intake restrictions. Environmental and Usage Factors: cold-weather idling, infrequent exercise under load, and moisture accumulation. Consequences & Damage Cylinder & Ring Glazing Glazing smooths out honing patterns on cylinder walls, preventing oil-control rings from wiping excess oil and leading to blow-by and accelerated wear. Injector & Valve Fouling Sludge deposits on injectors and valves disrupt spray patterns and airflow, impairing combustion and raising emissions. Oil Dilution & Corrosion Unburned fuel washes into the crankcase, diluting oil, lowering viscosity, and forming corrosive acids that damage bearings and camshafts. Exhaust & Turbocharger Impact Oily deposits in turbochargers and exhaust piping increase back-pressure, reduce efficiency, and clog after-treatment devices. Performance & Emissions Rough running, stalling, or hard starting Higher fuel consumption for the same power Failed emissions systems risk regulatory non-compliance Prevention Strategies Regular Load-Banking: Frequency: at least monthly Procedure: run at 30–75% load for 30–60 minutes to burn off deposits Proper Sizing: Select a generator whose typical load sits above 40% of capacity; consider paralleling smaller units if demand is intermittent. Consistent Real-World Operation: Utilize real loads (HVAC, pumps, lighting) rather than extended idle periods; simulate loads as necessary. Fuel Quality & Stabilization: Use ultra-low-sulphur diesel, keep tanks topped up, and add stabilizers for storage over 30 days. Routine Maintenance: Follow Perkins or Caterpillar recommended intervals for oil and filter changes, air filter replacements, inject

2. 

   17 Jun 2025

   Perkins Engine Warranty – 6000 Hours!

   Episode DescriptionAurora Generators has teamed up with Perkins® to deliver an offer that redefines peace of mind for backup-power owners. In this episode, we break down how the new promotion upgrades every 10 kW and 13 kW Aurora diesel generator with FREE Perkins Platinum Protection—doubling engine coverage to four years or 6000 hours. You will hear why extending the standard 2-year/3 000-hour warranty matters for homes, farms, tele-sites, and off-grid cabins that cannot afford downtime.We start with the fundamentals: what makes a Perkins liquid-cooled diesel so different from gasoline, propane, or air-cooled units? Lower fuel burn (≈ approximately 0.5 gal/hr at 10 kW), rugged 20,000-hour life-to-overhaul, and whisper-quiet operation, thanks to oversized radiators and sound-attenuated enclosures. Then we dive into the details of Platinum Protection itself: zero deductibles, 100 % parts-and-labour coverage, factory-trained technicians who come to you, and complete transferability if you ever sell the set. For most buyers, that package would cost about a few hundred dollars, but Aurora is absorbing the fee during this launch window.Aurora will automatically register your warranty for an Aurora Diesel Generator powered by Perkins engines.  You just need to keep to the normal maintenance schedule. The rest of the generator (alternator, controls, tank, enclosure) continues to be backed by Aurora’s five-year comprehensive warranty.Whether you’re designing an off-grid solar system, safeguarding a business, or just tired of unreliable portable generators, this conversation explains why now is the smartest—and least expensive—time to step up to an Aurora Perkins diesel generator set.

3. 

   13 Jun 2025

   PTO Generators

   What Is a PTO Generator and Who Uses Them? A Power Take-Off (PTO) generator is a mobile electrical power unit that draws its mechanical energy directly from the PTO shaft of an agricultural tractor, truck, or other heavy-duty vehicle. Instead of relying on a self-contained engine, a PTO generator harnesses the engine power of the host vehicle—making it an efficient, space-saving solution for on-site electricity needs. How PTO Generators Work Connection: The generator’s input shaft is linked to the vehicle’s PTO output via a splined coupling. Drive: As the vehicle’s engine runs and engages the PTO (typically at 540 or 1,000 RPM), it spins the generator’s rotor. Generation: The rotor’s motion within the stator windings produces alternating current (AC), which is then conditioned by on-board regulation equipment to provide stable, usable power. Key Features & Benefits Compact Design: Without an integrated engine, PTO generators are smaller and lighter than standalone units. Cost Efficiency: Shared use of the host vehicle’s fuel and maintenance schedule reduces total cost of ownership. Flexibility: Operators can switch the generator between multiple tractors or trucks, adapting to seasonal or evolving workload demands. Rapid Deployment: Hook-up to the vehicle’s PTO is straightforward, allowing power on-demand for short-term tasks. Who Uses PTO Generators? Farmers & Agricultural ContractorsRunning irrigation pumps, grain augers, milking parlors, or fencing equipment in fields without fixed power. Construction & Site ContractorsPowering lighting towers, compressors, and small machinery on remote job sites without hauling separate generators. Utility & Maintenance CrewsProviding spot power for tools and lighting during roadside or rail repairs using truck-mounted PTO units. Event & Rental ServicesSupplying temporary power for outdoor concerts, fairs, and emergency shelters via rented tractors or trucks. Is a PTO Generator Right for You? If you already operate tractors or heavy vehicles and need intermittent or remote power—especially in agricultural, construction, or utility contexts—a PTO-driven generator may be the most economical and adaptable choice. By leveraging existing equipment, you gain dependable electricity with minimal additional investment and upkeep.

4. 

   3 Jun 2025

   Why Won’t My Portable Generator Start?

   Portable gas-powered generators are indispensable during power outages, camping trips, or when working in remote areas. But what happens when you go to start your generator, and nothing happens? One of the most common culprits is fuel-related issues. In this blog, we’ll explore the top fuel-related reasons your gas generator may not start and offer practical tips for troubleshooting and prevention. 1. Fuel Degradation: The #1 Starting Problem Gasoline doesn’t last forever. Fuel can start to degrade in as little as 30 days, especially when exposed to air and temperature fluctuations. As gasoline ages, it oxidizes and forms gums and varnish that clog the carburetor’s tiny jets and passages, restricting fuel flow to the engine. Signs of bad fuel: Strong, sour odour Darker colour than fresh gasoline Sluggish or no engine turnover Solution: Drain old fuel from the tank and carburetor bowl. Refill with fresh gasoline. Add a fuel stabilizer, such as STA-BIL, to extend fuel life, especially before storage. After adding stabilizer, run the generator for a few minutes to circulate it throughout the system. 2. Water Contamination in Fuel Condensation in fuel tanks or contaminated storage containers can introduce water into your gasoline. Water does not burn and can prevent proper combustion or even corrode internal components. Symptoms: Sputtering engine Failure to start White smoke or steam from the exhaust Solution: Drain the tank completely. Refill with fresh, dry fuel. Consider using a fuel-water separator or ethanol treatment if you're in humid environments. 3. Ethanol-Blended Gasoline Problems Most pump gas today contains up to 10% ethanol. While legal and widespread, ethanol has downsides in small engines: Attracts moisture, leading to phase separation Accelerates corrosion in metal components Forms gummy deposits when left unused Best practices: Use ethanol-free gasoline if available (often sold at marinas or premium gas stations). Always use a fuel stabilizer designed to combat ethanol-related issues. Run your generator dry or drain the carburetor if you plan to store it for long periods. 4. Clogged or Gummed-Up Carburetor Even if you’ve put fresh gas in the tank, residue from degraded fuel may already be clogging the carburetor. This restricts the air-fuel mixture needed for combustion. Symptoms: Generator starts, then stalls No start despite a full tank and a working spark plug Solution: Remove the carburetor and clean it thoroughly. Spray carburetor cleaner into jets and passageways. Use compressed air to clear debris. If needed, install a carb rebuild kit. 5. Fuel Valve or Fuel Line Blockage A closed or clogged fuel valve will prevent gasoline from reaching the carburetor, even if your tank is full. Quick checks: Ensure the fuel valve is open. Remove the fuel line to confirm that gasoline flows freely. Replace fuel filters or lines if clogged or brittle. 6. The Generator Is Flooded With Fuel Repeatedly trying to start your generator, especially with the choke on, can flood the engine. Too much fuel in the combustion chamber prevents ignition. Solution: Let the generator sit for 10–15 minutes to allow excess fuel to evaporate. Avoid repeated cranking with the choke fully on. Ensure proper choke settings when starting. Preventive Maintenance: Your Best Defence Routine generator maintenance can prevent most fuel-related starting issues: Change the oil as recommended Replace the spark plug annually or after extended use Clean the air filter regularly Drain the carburetor if storing for more than a month Run the generator monthly to keep fuel flowing and prevent magnetism loss Most portable generator starting problems are simple to fix, especially when the issue is fuel-related. Regular maintenance, fresh gasoline, and proper stor

5. 

   3 Jun 2025

   Fixing Portable Generators – No Output Power

   Why Your Generator Runs But Produces No Power – The Role of Residual Magnetism If your portable generator runs but doesn’t produce power, you’re not alone. This is one of the most common generator troubleshooting issues reported by homeowners, contractors, and RV owners. Understanding why a generator runs but has no voltage output is essential for restoring power quickly, especially when backup power is critical. One of the primary culprits? Loss of residual magnetism. What Is Residual Magnetism and Why Does It Matter? All generators rely on magnetism to create electricity. When your generator starts, a small amount of magnetism—known as residual magnetism—is used to generate an initial low voltage, which then feeds into the excitation system to produce full power. Without this leftover magnetism from a previous run, the generator has no way to “kick-start” the process of power generation. “If residual magnetism is lost, your generator will produce no power at startup.” — Why Does My Generator Run, but Not Produce Electricity? Common Causes: Why Residual Magnetism Is Lost If you’re wondering why your generator is running but not generating electricity, here are some common causes of residual magnetism loss: Prolonged storage or inactivity Shutting down with a load connected Running the generator without a load for too long Transport vibration (common with new generators) Fuel starvation under load (e.g., generator runs out of fuel mid-use) “Loss of residual magnetism may be caused by having a connected load when the generator is shut off, or by running your generator for too long with no load.” — Fixing Portable Generators with No Power Other Common Reasons a Generator Produces No Power While residual magnetism is the most common issue, it’s not the only reason a generator has no voltage output: ✅ Tripped breaker or GFCI Always verify that all breakers are reset and functioning properly. ✅ Faulty AVR (Automatic Voltage Regulator) A failed AVR can prevent voltage build-up. ✅ Damaged capacitors Some generators use a capacitor instead of an AVR to build voltage. ✅ Worn carbon brushes or slip rings These are essential for transferring power from the rotor to the stator. ✅ Excitation winding issues Broken or grounded windings prevent the generator from energizing. How to Restore Power: Flashing a Generator When residual magnetism is gone, it can often be restored using a process called flashing the generator. Here are two proven methods: 1. The 12V Battery Method Disconnect the AVR or excitation wire (consult your generator manual). Briefly apply 12V DC from a car battery to the field windings. This jumpstarts the magnetic field needed for power production. “The 12-Volt Generator Battery Method involves applying battery voltage to the excitation circuit to rebuild magnetism.” — Fixing Portable Generators – No Power 2. The Electric Drill Trick Plug a corded drill into the generator. Start the generator with the drill’s trigger pressed. Spin the drill chuck backwards by hand. This sends a small current back into the generator. “The corded drill trick works as a way to field-flash a generator and restore power output.” Preventing Future Power Loss To ensure your generator always produces power, follow these best practices: ✅ Run the generator under load regularly ✅ Disconnect all loads before shutdown ✅ Avoid fuel starvation while under load ✅ Store and transport your generator carefully to avoid vibration damage “Always run your generator with a load and disconnect that load before you turn the generator off.” When to Call a Generator Repair Professional If your generator still runs but produces no electricity after flashing or basic troubleshooting, it’s time to call a qualified technician. Complex electrical issues—such as excitation circuit failures or AVR problems—often requir

6. 

   2 Jun 2025

   DynaGen Wiring Harnesses

   Why Use a Pre-Made DynaGen Wiring Harness? Using a DynaGen pre-fabricated wiring harness offers several significant advantages: Saves Time and Effort Harnesses like DWG1476, DWG1477, and DWG1478 come with standard connectors that match DynaGen controller terminals, making installation quick and hassle-free. Reduces Wiring Errors Each wire is labelled, colour-coded and properly terminated, minimizing the risk of incorrect connections that could damage the controller or cause system failures. Clean, Professional Installation Pre-bundled cables reduce clutter, improve serviceability, and enhance the overall appearance of the wiring setup. Ensures Compatibility These harnesses are designed explicitly for DynaGen controllers, including the TG350, TG410, TE600, and TG600, ensuring correct pin assignments and reliable operation. Enables Advanced Features Advanced models, such as the DWG1477, support features like CANbus, Modbus, and sensor integration (e.g., Sensata oil pressure sensors), streamlining the installation and configuration of complex systems. Pre-terminated harnesses are particularly useful in mobile or outdoor generator setups, where durability, uptime, and ease of service are crucial. These harnesses are standard accessories across multiple DynaGen controller lines, and their use is typically recommended in wiring diagrams and manuals for models like the TE350, TE410, TG350, and TG410.

7. 

   2 Jun 2025

   Introduction to DynaGen Controllers

   In this episode, we are discussing generator instrumentation, protection, and control. Aurora Generators is an authorized distributor of DynaGen engine and generator controllers. We deliver across North America and fully support DynaGen products. Find out what makes these generator controllers so tough and why your generator needs one.

8. 

   2 Jun 2025

   Gas vs Diesel Generators

   Summary Diesel generators have long been the workhorse of critical-power applications—from hospitals and data centers to remote off-grid installations—because of fundamental differences in their thermodynamics, mechanical design, and operational characteristics. 1. Higher Thermal Efficiency and Lower Fuel Cost Compression Ignition vs. Spark Ignition Diesel engines compress air to very high pressures (ratios of 14:1 to 22:1), heating it until injected fuel auto-ignites. Gasoline engines use spark plugs at lower compression (8:1–12:1), limiting efficiency. Higher Energy Density Diesel fuel delivers about 38.6 MJ per liter versus 34.8 MJ/L for gasoline, yielding more work per volume. Brake Specific Fuel Consumption (BSFC) Modern diesel gensets achieve ~185–200 g/kWh, while small gasoline units often exceed 300 g/kWh—burning 30–40% less fuel per kWh. 2. Robust Mechanical Design and Reduced Maintenance Heavy-Duty Construction Engine blocks and major components are made of thick cast iron or forged steel to withstand high pressures, unlike lighter aluminum in gasoline units. Simplified Auxiliary Systems No spark plugs, distributors, or carburetors—just sealed, precision fuel injectors. Fewer wear items mean fewer maintenance tasks. Longer Service Intervals Industrial diesels often go 2,000–4,000 hours between major overhauls (10,000+ hours on large standby units), compared to 500–1,000 hours for gasoline engines. 3. Extended Longevity Lower Engine Speeds Running at 1,500 RPM (50 Hz) or 1,800 RPM (60 Hz) cuts cumulative wear by 30–50% versus 2,000–4,000 RPM in gasoline engines. Oil Cooling and Filtration High-capacity sumps, full-flow and bypass filters, and oil coolers keep contamination low and extend component life. Tough Wear Surfaces Hardened liners and coated piston skirts resist scuffing, delivering 10–30× the lifespan of similar gasoline engines. 4. Suitability for Heavy-Duty and Continuous Applications High Torque Output Peak torque at low RPM handles heavy or reactive loads (compressors, pumps) without stalling. Ambient and Altitude Performance Better cold-start and high-altitude operation, often without the need for block heaters or special kits. Fuel Flexibility Can run on biodiesel blends (B20–B100), waste oils, or low-grade distillates with minimal modifications. Analogy: Think of a diesel generator like a heavy-duty semi-truck engine versus a gasoline car engine. The truck’s engine is built thicker, runs slower under higher pressures, and hauls massive loads for hundreds of thousands of miles before overhaul. In contrast, a car engine, optimized for lighter loads and higher speeds, wouldn’t survive industrial duty.

9. 

   2 Jun 2025

   Diesel Engine Break-In

   Why Proper Engine Break-In Matters for Diesel Generators When you invest in a diesel-powered generator, you're buying into reliability, durability, and long-term performance. But what many operators overlook is the critical importance of engine break-in—a process that directly influences how well your generator performs and how long it lasts. In this post, we'll explore why break-in matters, how it works, the risks involved when it's done improperly, and the role tribology—the science of friction, wear, and lubrication—plays in generator performance. We’ll also address specific concerns, such as wet stacking and under-loading, which are particularly relevant in diesel generator applications. What Is Engine Break-In and Why Is It Necessary? Engine break-in (also called mechanical run-in) is the initial period of operation where the moving parts—especially the piston rings and cylinder walls—gradually wear against each other to form a tight, efficient seal. This controlled wear process is critical for: Establishing optimal compression Preventing excessive oil consumption Reducing blow-by (combustion gases leaking past the piston rings) Break-in isn't just a suggestion; it’s engineering in action. During this stage: Cylinder walls, although they may appear smooth, are actually honed with a cross-hatch pattern of peaks and valleys. The peaks are worn down during break-in, while the valleys retain oil, promoting proper lubrication. Adequate load must be applied to create the necessary pressure (BMEP) to press the piston rings against the cylinder walls. Failing to apply enough load during break-in can lead to cylinder glazing, where the surface becomes too smooth for proper ring seating, causing permanent damage unless re-honed. Tip: Always change the oil early in the engine’s life to remove metal particles created during break-in. The Science Behind It: Piston-Cylinder Tribology The piston-cylinder system is one of the most complex parts of an internal combustion engine. It involves: Dynamic motion and deformation of the piston Micro-scale lubrication between the piston skirt and cylinder liner Mixed lubrication regimes where both oil film and surface contact coexist This field—called tribology—influences engine friction, heat generation, wear rates, and oil retention. Key takeaways include: Plateau honing is used on cylinder liners to improve oil retention. Surface roughness and bore distortion significantly affect piston ring sealing. Modeling tools (like Reynolds equations and FEM simulations) help engineers understand these interactions and improve designs. During break-in, tribological models even show a decrease in frictional losses (FMEP), stabilizing once surface wear reaches an optimal level. Diesel Generator Operation: Why Under-Loading Is a Problem Diesel generators often face a unique challenge—they’re underloaded most of the time. That’s because they’re typically sized for peak demands (e.g., air conditioner startup) but run at lower loads during regular operation. This creates a condition called wet stacking, where unburned fuel and carbon accumulate in the combustion chamber and exhaust system. It results in: Reduced efficiency Increased emissions Potential engine damage Prevention strategies include: Running the generator at 70%–80 % load during break-in Scheduling regular load bank tests to simulate full power demand Avoiding prolonged light-load operation Remember: Proper break-in isn’t just about starting the engine—it’s about running it at the right load for the right duration. Maintenance Matters: Supporting Long-Term Performance Break-in is only the beginning. A well-maintained diesel generator needs: Early and routine oil and filter changes Monitoring of fuel type and quality (e.g., avoid ethanol in gasoline generators) Compliance with scheduled maintenance intervals (

10. 

    2 Jun 2025

    Why Solar Homes Need Backup Generators

    Podcast Summary: Backup Power Solutions for Solar and Off-Grid Systems In this episode, we explore the critical role that backup power, particularly diesel generators, plays in supporting solar and off-grid power systems. Whether you're living off the grid, powering remote commercial operations, or preparing for emergencies, having a dependable backup energy source is essential. This podcast discusses the technical considerations, advantages, and best practices for integrating generators into solar systems. Key Topics Covered: Why Backup Power Matters Backup generators ensure continuous power during outages or periods of low solar production. In remote or off-grid locations, they’re not just a luxury—they’re a necessity. Diesel-powered generators are especially favoured for their reliability and ability to handle high-duty cycles in demanding conditions. Diesel Generator Benefits Long service life: Over 20,000 hours with proper maintenance Fuel efficiency: High compression ratios and better thermal efficiency than gas engines Safer storage: Diesel is less volatile than gasoline or propane Quiet and durable: 1800 RPM diesel engines run cooler and quieter Customization: Available in portable, permanent, and auto-start configurations Generator Sizing for Off-Grid Solar Proper sizing is essential to ensure reliability and efficiency. Consider: Battery charging load (inverter charging capacity in kW) Continuous critical loads (appliances, lighting, etc.) Surge/startup loads (motor-driven equipment) Add a 20–30% buffer above the calculated load Operate diesel generators at 60–80% load for longevity Example: Charging: 5 kW, Loads: 3 kW → Generator size: 12–15 kW Battery Technology Trends Lithium-ion batteries are replacing lead-acid systems due to: Compact size and modular design High energy density Low maintenance Safer chemistry NEC Code Considerations For safety and compliance, photovoltaic systems must meet NEC standards: Proper labelling of PV modules with ratings and polarity Correct crimping and wiring methods DC-rated overcurrent protection sized to 156% of short-circuit current Disconnects between batteries and inverters Voltage limits up to 600V with properly rated components Shock protection and warning signage are required Fuel Types and Storage While diesel is the preferred fuel, other options include: Propane: Long shelf life but relies on deliveries Gasoline: Not ideal due to volatility and poor storage characteristics Alternative fuels: Biodiesel, wood gas, and others are discussed as niche solutions Key Takeaways: Diesel generators offer unmatched durability and fuel efficiency Correct sizing ensures reliability and prevents engine issues Lithium batteries reduce maintenance and improve system performance NEC code compliance ensures safe and legal installation This episode is ideal for homeowners, off-grid builders, and professionals designing or upgrading hybrid solar-diesel systems. Learn more about reliable diesel backup power solutions at www.AuroraGenerators.com

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Podcast Authority Score: 27 / 100

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