GenX-500 Diesel Generating Set

August 7, 2026 · View on GitHub

SimGen Systems · 400 kW Prime / 440 kW Standby · 50 Hz · 400/230 V

This is a simulated device. SimGen Systems and the GenX-500 do not exist. The data below are ordinary engineering parameters for a mid-size industrial diesel generating set, chosen so that the simulation in GeneratorServer is physically self-consistent. They describe no real product.

Every value here is also a constant in GeneratorDatasheet.cs, which the server uses to build the address space and drive the simulation. GeneratorDatasheetConformanceTests fails the build if this document and the code ever disagree.

1 Product description

The GenX-500 is a skid-mounted, radiator-cooled diesel generating set for prime and standby duty. A turbocharged and aftercooled inline-six drives a four-pole brushless alternator through a flexible coupling; both are mounted on a welded steel base frame with anti-vibration mounts and an integral fuel tank.

A single control panel provides start/stop, mode selection, metering, protection and an OPC UA interface conforming to the Generators companion specification.

2 Nameplate

FieldValueOPC UA browse path
ManufacturerSimGen Systems2:Identification/2:Manufacturer
ModelGenX-5002:Identification/2:Model
Product codeGX500-400-50-4W2:Identification/2:ProductCode
Serial numberSG-500-<nnn>2:Identification/2:SerialNumber
Device classGeneratingSet2:Identification/3:DeviceClass
Hardware revision3.12:Identification/2:HardwareRevision
Software revision5.4.22:Identification/2:SoftwareRevision
Device revision3.1/5.4.22:Identification/2:DeviceRevision
Manufacturer URIhttps://simgen.example.com2:Identification/2:ManufacturerUri
Year of construction20252:Identification/3:YearOfConstruction
Month of construction42:Identification/3:MonthOfConstruction

Namespace prefixes: 2: = http://opcfoundation.org/UA/DI/, 3: = http://opcfoundation.org/UA/Machinery/, 4: = http://opcfoundation.org/UA/Generators/.

3 Ratings (ISO 8528)

DutyReal powerApparent powerApplication
PRP — Prime400 kW500 kVAUnlimited hours, variable load
ESP — Standby440 kW550 kVAEmergency use, varying load
ParameterValue
Rated power factor0.8 lagging
Rated line-to-line voltage400 V
Rated line-to-neutral voltage230 V
Rated line current at PRP721.7 A
Frequency50 Hz
Phases / wires3 / 4
Reference ambient25 °C
Reference altitude150 m

Rated current is not tabulated independently — it is I = S / (√3 · V_LL), so it cannot drift away from the rating it derives from.

4 Engine

ParameterValue
ConfigurationInline 6-cylinder, 4-stroke
AspirationTurbocharged, air-to-air aftercooled
Displacement12.5 L
Bore × stroke130 × 157 mm
Compression ratio16.5 : 1
Rated speed1500 min⁻¹
GovernorElectronic, isochronous
Oil pressure at rated speed4.8 bar
Thermostat opening82 °C
CoolingRadiator, engine-driven fan

Rated speed follows from the pole count and output frequency: N = 120 · f / p = 120 · 50 / 4 = 1500 min⁻¹.

5 Alternator

ParameterValue
TypeBrushless, self-excited, 4-pole
ConnectionStar (wye), 4-wire
Insulation classH
Voltage regulation±0.5 % steady state
PhasesL1, L2, L3 individually metered

6 Fuel system

ParameterValue
FuelDiesel
Base tank capacity1000 L
Reference fuel density0.832 kg/L
Reference lower heating value42.7 MJ/kg
Usable energy per litre9.868 kWh/L

7 Physical

ParameterValue
Length × width × height4.00 × 1.50 × 2.20 m
Dry mass4500 kg
Sound pressure at 1 m (enclosed)75 dB(A)

8 Characteristic curves

Load fraction x — electrical output as a fraction of prime power — is the only independent variable. Everything else follows from these curves, which is what keeps the published values mutually consistent at every tick.

8.1 Fuel consumption

The classic affine generating-set fuel map:

V̇_f(x) = 3.67 + 100.00 · x        [L/h]

8.2 Electrical efficiency

η(x) = P(x) / (V̇_f(x) · ρ · LHV)

with ρ · LHV = 9.868 kWh/L. Efficiency is therefore never an independent number: it always reconciles with the published power and fuel rate.

8.3 Thermal

T_coolant(x) = 82 + 13 · x        [°C]
T_exhaust(x) = 250 + 300 · x      [°C]

8.4 Electrical

S = P / PF                        [VA]
I = S / (√3 · V_LL)               [A]
f = N · p / 120                   [Hz]

9 Performance table

Derived from the curves in §8 — this table is generated by them, not independently asserted.

LoadReal powerFuel rateEfficiencyCoolantExhaust
10 %40 kW13.7 L/h29.65 %83.3 °C280 °C
25 %100 kW28.7 L/h35.34 %85.2 °C325 °C
50 %200 kW53.7 L/h37.76 %88.5 °C400 °C
75 %300 kW78.7 L/h38.64 %91.8 °C475 °C
100 %400 kW103.7 L/h39.10 %95.0 °C550 °C
110 %440 kW113.7 L/h39.22 %96.3 °C580 °C

At 1000 L usable capacity and full prime load the set runs for approximately 9.6 hours on a full tank.

10 Instrumentation

MeasurementUnit publishedEngineering rangeBrowse path
Engine speedmin⁻¹0 … 20004:Engine/4:Speed
Oil pressurePa0 … 8 bar4:Engine/4:OilPressure
Coolant temperatureK0 … 120 °C4:Engine/4:CoolantTemperature
Exhaust temperatureK0 … 700 °C4:Engine/4:ExhaustTemperature
Fuel ratem³/s0 … 120 L/h4:Engine/4:FuelRate
Engine hoursh—4:Engine/4:EngineHours
FrequencyHz45 … 554:Alternator/4:Frequency
Total real powerW0 … 550 kW4:Alternator/4:TotalRealPower
Average voltageV0 … 4804:Alternator/4:AverageLineVoltage
Average currentA0 … 8004:Alternator/4:AverageCurrent
Power factor—0 … 14:Alternator/4:AveragePowerFactor
Load percent%0 … 1204:Alternator/4:LoadPercent
Per-phase V/I/P/PFV/A/W/—as above4:Alternator/4:L1 … 4:L3
Fuel level%0 … 1004:FuelSystem/4:FuelLevel
Battery voltageV0 … 324:StartingSystem/4:BatteryVoltage

OPC UA publishes SI throughout: temperatures in kelvin, pressures in pascal, volumetric rates in cubic metres per second. The datasheet's own engineering units are converted on the way out.

11 Protection trip points

ProtectionTripEffect
Low oil pressure< 1.7 barShutdown
High coolant temperature> 98 °CShutdown
Overspeed> 1725 min⁻¹ (115 %)Shutdown
Overload> 110 % of PRPAlarm
Low fuel level< 15 %Warning
Low battery voltage< 22 VWarning

Protection events are reported as 4:GeneratorProtectionAlarmType, a subtype of OffNormalAlarmType, carrying the ProtectionFunction, severity, whether the event is a shutdown, and the originating subsystem.

12 Operating states

OperatingState is a 4:GeneratorStateMachineType with twelve states:

stateDiagram-v2
  [*] --> Off
  Off --> Ready
  Ready --> Starting
  Ready --> Off
  Starting --> Warmup
  Starting --> Fault
  Warmup --> Running
  Running --> Loaded
  Running --> Cooldown
  Running --> Fault
  Loaded --> Cooldown
  Loaded --> Fault
  Cooldown --> Stopping
  Stopping --> Off
  Fault --> Off
  Running --> EmergencyStopped
  Loaded --> EmergencyStopped
  EmergencyStopped --> Off

OperatingMode reflects the panel selector: Off, Manual, Auto, Test, Exercise, RemoteStart, Maintenance, Lockout.

13 Process schematic

flowchart LR
  TANK[("Fuel tank<br/>1000 L")] -->|"V̇_f(x)"| ENG
  AIR([Intake air]) --> TC[Turbocharger]
  TC --> AC[Aftercooler] --> ENG
  ENG[["Engine<br/>12.5 L inline-6<br/>1500 min⁻¹"]] --> CPL{{Coupling}}
  CPL --> ALT[["Alternator<br/>4-pole brushless<br/>400 V 50 Hz"]]
  ENG -->|exhaust| SIL[Silencer] --> STK([Stack])
  ENG <-->|jacket water| RAD[Radiator + fan]
  ALT --> BRK[/Breaker/] --> BUS([Load bus])
  BATT[("Battery<br/>24 V")] --> STR[Starter] --> ENG
  CTRL[Controller] -.->|start / stop / mode| ENG
  ALT -.->|V, I, f, PF| CTRL
  ENG -.->|speed, oil, coolant| CTRL

14 Simulation profile

The server does not replay a recording. It integrates the model above:

  1. Load fraction is driven around a nominal 72 % with an 18 % swing, phase shifted per set so no two sets in a plant report the same duty point.
  2. Real power, apparent power, per-phase voltage and current, frequency, fuel rate, efficiency, coolant and exhaust temperature all follow from that single value through §8.
  3. Engine hours, total real energy and fuel consumed are integrated over time.
  4. Protection states are evaluated against §11 with hysteresis, so an alarm latches and clears cleanly rather than chattering on the threshold.
  5. The operating state machine advances through §12, staged per set so that a plant shows sets in different states simultaneously.

Because power and fuel rate are both functions of the same load fraction, η = P / (V̇_f · ρ · LHV) and P = √3 · V · I · PF hold at every published sample — which is exactly what the conformance tests assert.