Custom Build Project: Supplying PNG with Custom Isuzu Generators

Genelite has completed the engineering, control integration and factory testing of two 250 kVA Isuzu powered generator sets for a client in Papua New Guinea. The units were supplied as separate engine and alternator assemblies, requiring a complete system design to convert them into fully operational generator sets capable of prime and standby duty.

Central to the design is the renowned Isuzu engine, which has earned a reputation for reliable operation in harsh environments. The work involved mechanical and electrical integration, full control system engineering and verification of generator performance through controlled load testing. The outcome is two robust generator systems engineered for reliable operation in remote and demanding environments.

Control Architecture and ECU Integration

The project involved the installation and configuration of a ComAp AMF25 automatic mains failure controller. This digital interface allows the controller to read key engine parameters directly from the ECU, including speed, coolant temperature, oil pressure, fault codes and operating status.

The ComAp AMF25 was programmed to manage all generator protection, start and stop logic, voltage and frequency regulation, and to interface correctly with the MeccAlte alternator’s AVR system. The configuration ensures stable operation under varying load conditions and provides the operator with advanced monitoring and reporting capabilities.

System Build and Electrical Integration

Since the engines arrived without any control or auxiliary systems, Genelite’s engineering team installed the generator control panel including circuit protection, instrumentation, auxiliary relays, battery management and safety interlocks.

Mechanical fit-out includes mounting provisions, cable routing, fuel system connections and vibration isolation. All wiring was completed to Genelite’s engineering specifications, ensuring correct termination, shielding and earthing suitable for continuous-duty operation.

Following installation, the full system underwent functional testing, including CAN communication validation, simulated fault testing, control sequence verification and load bank testing to confirm output stability and alternator performance.

Built for Field Reliability

Both generator sets are now configured for deployment in PNG where durability, reliability and serviceability are critical. The final systems provide efficient control, stable electrical output and comprehensive engine protection, ensuring dependable operation in remote field conditions.

Engineering Capability Beyond Standard Supply

This project highlights Genelite’s capability to engineer complete generator systems from componentry. By combining advanced controller integration, ECU communication, precision electrical design and load-tested verification, Genelite ensures every system meets the performance and durability requirements of industrial and remote applications.

Genelite continues to support commercial, industrial and infrastructure clients across Australia and the Pacific with custom built power solutions, designed for long-term performance and durability.

Contact the Genelite team today on 1300 305 912 to find the right solution for your needs.