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Quick guide: components for your industrial generator

clock 10 minutes | 03 Dec 2020

Industrial generator

Whether you’re designing an electric or diesel generator, you need to give careful consideration to the components you’ll need. Your generator parts will range from handles and heavy-duty door latches to cable ties and PCB standoffs.

This is a general guide, designed to help you make these and other choices. Generators vary, of course, and components shown here – for example, an inspection window – are typically placed on the generator panel either in the front or side. All the components recommended here suit generators, no matter where you place them.

To further help you design your industrial generator, we’ve made free CADs of our solutions available for download. You can also request free samples, which are available for many of our solutions, so you can try before you buy.

Ideal industrial components

The main assembly frame houses your generator. This is what industrial generator parts are built onto. Outdoor generators should be enclosed in a protective frame. Indoor generators can be an open design – or open frame – but for extra protection and sound dampening, consider a closed design, also called canopied. Here are the components we recommend for building a generator enclosure and for the generator itself.

Front and back doors

Whether your generator has one or two doors, consider using the following components.

Front and back door of industrial generator
​Locking paddle latch

Locking paddle latch

Heavy-Duty door Latch with cam push lock available in keyed alike or keyed to differ. The lock can be opened from the inside by moving the brass cam. Complies with IP54 rating to protect against dust ingress. Choose between silver or black powder-coated finish. Available in stainless steel zinc alloy and nylon.

​Flush-cup recessed T-handle latch

Flush-cup recessed T-handle latch

Handles for generators designed for flush-mounting to help avoid snagging of clothing or skin. Made of stainless steel and also available as a T-handle cam lock, with a steel cam.

​Free swinging hinge – leaf

Free swinging hinge – leaf

Threaded stud-mount leaf for flush-mounted heavy doors, with a maximum hinge rotation of 270°. This type of heavy-duty butt hinge is designed for security, with concealed mounting screws that prevent external access to the hinge. Suitable for left- and right-hand applications. Made of zinc alloy.

​Free Swinging hinge – countersunk mount leaf

Free Swinging hinge – countersunk mount leaf

Strong, tamperproof heavy-duty steel hinges provide a 270° rotational angle. Generally used for plain/flush mounted, isolated, heavy doors. Attached by screws or nuts and bolts and has a black powder-coated finish.

​Quarter turn latch with wing knob with extra-long housing

Quarter turn latch with wing knob with extra-long housing

Perfectly suited for isolating noise produced by generators. Supplied with a rubber gasket for additional sealing. Die-cast zinc alloy with chrome plating or black powder-coated finish, and steel cam.

​Sealing gaskets

Sealing gaskets

Push-on trim in different styles, including side bubble gasket seals. Provides additional seal and protection from the generator’s vibrations. Also protects against humidity and dirt ingress. Available in EPDM and PVC. You can also use weather stripping tape and gasket tape. Perfect for outdoor generators, the tapes’ cell foam provides corrosion resistance and barrier protection against the elements.

​Recessed handles

Recessed handle

Recessed pull handles come in different styles and snap easily into place. Ideal for safety concerns by avoiding sharp edges. These plastic recessed handles are made of acrylonitrile butadiene styrene (ABS). While ABS can be used outdoors, it will have longer life on an indoor generator.

Side panel and control panel

If your generator’s control panel will rely on printed circuit board mounting hardware, we’ve included those solutions here. Often, control panels are located on the side of a generator, but this is not a hard-and-fast rule.

Generator side panel and control panel
​Fan guards

Fan guards

Metal fan guards prevent debris falling into the fan blades and causing obstructions while preventing bodily harm. The screw mount application makes it easy to install. Steel-wire electroplated material resists corrosion.

​Thumb screw knobs – round

Thumb screw knobs – round

These plastic knobs cap off standard socket cap head screws, creating a basic round thumb screw. Available in white, natural, green, blue and red screw knobs. You can also choose black plastic knobs.

​Inspection windows

Inspection windows

View counters, dials, and instruments from outside the generator. You can ensure their good working order with the supplied sealing o-ring that prevents dirt and moisture ingress. Made of strong polycarbonate.
​Female-to-female standoff

Female-to-female standoff

If your generator’s control panel includes a printed circuit board design, you’ll need to think about PCB hardware components. These round female-to-female PCB standoffs have a hexagonal bottom. They act as standoff insulators and are installed by hand without the need for assembly tools. These metric threaded standoffs are made of nylon 6/6 with brass inserts, and also available in male-to-female. Operating temperature range of -40°C to 105°C.

​PCB edge-locking supports – snap in

PCB edge-locking supports – snap in

Another useful PCB hardware design for the generator’s control panel. Edge locking supports securely hold the side of the PCB. The snap-in fitting and locating nose enables for quick assembly and easy removal for service. This locking PCB support is made of nylon. Operating temperature range of -40°C to 85°C.

​Non-threaded spacer – ceramic

Non-threaded spacer – ceramic

These ceramic spacers are installed by hand without the need for assembly equipment. Operating temperature range of -40°C to 1700°C.

​LED lens holders

LED lens holders

Generator control panels using LED lights will need an LED lens covers. These are designed to hold a standard T-1 3/4 LED while transmitting light at a 10˚ angle. Available with or without a sealing o-ring and made of strong polycarbonate with an operating temperature range of -40˚C to 130˚C.

​Fan filters – metal

Fan filters – metal

Keeping your control panel’s electronics cool involves fan filters and guards. This metal fan filter also acts as a metal fan guard. Prevents debris falling into the fan blades and causing obstructions. Made of aluminium with a stainless-steel filter.

You should also make sure you use fan gaskets to provide a protective seal.

​Fan rivets – snap

Fan rivets – snap

Snap rivets designed for fast assembly and cost savings. They mount fans, eliminating the need for a screw-nut combination. The prongs expand to hold securely as the pin is driven in. These snap-rivet fasteners are made of nylon 6/6 with an operating temperature range of -40˚C to 115˚C.

Top panel

Generator manufacturers have to transport their power generator to the customer. This is where the top panel becomes important.

Generator top panel
Hoist rings – safety engineered

Hoist rings – safety engineered

For outdoor generators and indoor generators alike, safety engineered hoist rings are critical for safe overhead lifts. Available in alloy steel and stainless steel 300 to resist corrosion. Always use high-strength screws to meet maximum load capacities.

Standard hex nuts – metal

Standard hex nuts – metal

Standard hex nuts are used with anchors, bolts, screws, studs, threaded rods and on any other fastener that has machine screw threads. The hexagonal shape means they’re easy to fasten or, if needed, loosen. Available in mild steel or stainless steel to resist corrosion. To get more friction and prevent the hex nut from loosening, use with single wave spring washers.

Generator

Beyond the housing and control panel, there’s the generator itself. Consider these components:

Side view generator
​Mounting cable ties – screw

Mounting cable ties – screw

Screw mount cable ties offer a cable tie and a mount all in one, which makes the mounting process faster. These screw mounts offer the additional benefits of an even more secure fastening. Made of nylon 6/6 and ideal for indoor generators.

​Standard cable ties – locking, weather resistant

Standard cable ties – locking, weather resistant

Weather-resistant cable ties are also UV resistant, making them perfectly suited for outdoor generators. A built-in lock system prevents accidental removal. Made of black nylon 6/6.

T-bolt hose clamps

T-bolt hose clamps

The vibrations produced by generators requires a strong seal for your hoses. These stainless-steel T-bolt hose clamps are ideal for providing the seal you need. The hex nut allows you to apply or remove it with standard tools.

​Cable conduit – plastic

Cable conduit – plastic

Minimise vibration with flexible cable conduit for your electrical connections to the generator’s conduit box. Available in nylon, HDPE and PP, this is highly flexible with a high fatigue life. When crushed, its high impact strength aids its recovery. It's also self-extinguishing and has high UV resistance. Flame retardant with high resistance to solvents and oils.

​Vibration mount standoffs

Vibration mount standoffs

Generator parts – especially the engine – vibrate, which can cause components to loosen. These vibration mount standoffs act as a buffer by absorbing vibrations. They also help reduce noise. Made of neoprene rubber and steel with an operating temperature range of -40°C to 80°C.

Under the generator

The main frame assembly, or skid, support heavy-duty generators while grounding them for safe operation. This can be designed so that the generator sits on the ground or floor, on a concrete plinth – or even on a trailer so that it can be transported to different sites. To protect your generator against vibrations, consider these components, placed between the generator and the skid.

Generator base
​Anti-vibration mounts – heavy-duty industrial

Anti-vibration mounts – heavy-duty industrial

To protect parts from vibration created by generator power systems, use heavy-duty industrial anti-vibration mounts. Their high-strength sandwich-mount construction reduces shock and vibration by up to 80%. The large support plate provides precision levelling and prevents walking or slipping out of position. Made of rubber and steel.

​Vibration mounts – heavy duty

Vibration mounts – heavy duty

Heavy-duty screw-on vibration mounts are perfect as feet for different types of generators. They absorb shock and reduce noise with high adhesion to the floor. Made of TPE.

​Stud mount levelling feet

Stud mount levelling feet

Ideal for a portable generator or one taken to use at different sites. The adjustable feet have a plastic rigid base and protect against vibration. Adjust the feet to any unlevel surface. Choose among a variety of materials: steel or low carbon steel and for your base, nylon, LDPE, PP, rubber, PU – or all plastic, made in PP or PE.

​​Rubber covers and pads – non slip

Rubber covers and pads – non slip

Non-slip rubber pads cover industrial adjustable levelling feet. These pads can bear heavy loads and provide extra friction to prevent movement and slipping. Available as a rubber pad for bolting to the surface.

​Castor wheels – fixed plate

Castor wheels – fixed plate

A generator for industrial use will require a skid, but if you’re designing a portable generator, then rubber castors with a fixed plate are ideal. The castors provide a full 360˚ rotation, with brakes allowing for a full stop. Maximum load is 125kg. If you need heavy-duty castor wheels – that is, something that can bear a heavier load – then consider rigid-plate castors. You can view our full range of castor wheels here.

Download free CADs and try before you buy

Free CADs are available for most solutions. You can also request free samples to ensure the solutions you’ve chosen are exactly what you need. If you’re not quite sure which product will work best for your application, our experts are always happy to advise you.

Whatever your requirements, you can depend on fast despatch.

Request your free samples or download free CADs now.

Questions?

Email us at sales@essentracomponents.co.uk or speak to one of our experts for further information on the ideal solution for your application 0845 758 5070.
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