How Often Should I Exercise my Generator?

Running an industrial generator might not be on your daily checklist, but keeping it in top-notch condition certainly should be! If your building depends on backup power to keep everything running smoothly in emergencies, routine generator testing and exercise are essential. A generator that’s left idle too long can lose its edge, costing you downtime and money if it doesn’t perform when you need it most. So, how often should you run that generator to ensure it’s ready to go? Here’s a simple breakdown to help you keep your equipment in prime condition.

Regular Testing for Reliable Performance

At a minimum, most manufacturers recommend running your generator at least once a month. This is known as a “no-load” test, meaning the generator runs without powering any of your building’s equipment. Think of it like starting up your car in the winter – it keeps the engine parts lubricated and ensures everything’s ready to go when you are.

To really put your generator to the test, though, you’ll need to go beyond monthly no-load testing. Industry best practices suggest a quarterly “load test” that simulates actual usage conditions. During this test, your generator runs at a set percentage of its total capacity, ensuring it can handle the demand your building would require in a real power outage. This testing exposes potential issues in advance, helping you avoid those unwelcome surprises during an actual emergency.

The Importance of Exercise Cycles

For an industrial generator, exercise cycles are critical to overall maintenance. Regular exercise cycles help prevent moisture buildup in the engine and keep fuel lines clear. A generator that sits idle too long can develop issues like battery failure, fuel degradation, and even corrosion – all issues that are easily avoidable with proper exercise.

To set a routine that’s in line with best practices, schedule your generator’s exercise cycle at least every two weeks. This schedule strikes a good balance between keeping the generator “limber” without overburdening it. If your building has specific backup power needs, like sensitive data storage, critical refrigeration, or healthcare facilities, this bi-weekly schedule can be particularly useful.

Tips for Smooth Operation and Longevity

Monitor Run Hours: Keep a log of every time the generator is exercised. This not only provides insight into its performance over time but also can be invaluable for your maintenance provider to diagnose issues early.

Check Battery Health: Many generator failures stem from battery problems, especially if they sit for extended periods without charging. During your regular testing, take a moment to check battery health or arrange for a professional inspection to ensure it’s in good shape.

Pay Attention to Load: Run your generator under varying load levels during tests. Generators perform best when they’re exercised close to the level they’d operate at during a power outage. Consistently running under light loads can cause carbon buildup on internal components, which, if unchecked, can lower performance.

Evaluate Fuel Quality: For diesel-powered generators, fuel stability is a key factor. Diesel fuel can degrade over time, and contaminants can build up if it sits unused for months. Testing the fuel periodically and arranging for fuel polishing if needed can make a big difference in performance when it counts.

Setting Up a Maintenance Partner

Whether you manage one building or a portfolio, a solid relationship with a generator maintenance partner makes all the difference. Many of these providers offer maintenance packages that include both scheduled testing and as-needed support. They’ll keep track of when it’s time to run those all-important load tests, check on battery and fuel health, and inspect your system so it’s always ready. And if your generator is handling more than just a few lights and AC units – like keeping security, emergency lighting, or other critical systems operational – this partnership is even more important.

When In Doubt, Consult Your Manufacturer’s Recommendations

Most generator manufacturers provide detailed maintenance schedules and testing recommendations, which are invaluable for maximizing your unit’s lifespan. Following these guidelines not only ensures that your generator performs when needed but also helps maintain your warranty coverage.

Final Thoughts

Running your industrial generator regularly is like an insurance policy on your building’s power – a small investment that ensures reliable operation when you need it most. By setting up monthly no-load and quarterly load tests, running bi-weekly exercise cycles, and keeping tabs on maintenance, you’re taking all the right steps to protect your building from the unexpected.