Why Generac generators are more reliable

Generator performance is subject to a variety of reliability challenges ranging from maintenance issues to circuit board failure to fuel quality and availability. The marketplace has tended to tolerate performance standards that are less than optimal, so over the years it has been Generac's mission to design generators that are significantly more reliable than the market norm. To accomplish these self-imposed higher quality standards, Generac addresses key reliability issues through superior product design.

Lack of Maintenance
Just as with the family car, generators require routine maintenance, i.e. periodic oil changes and the replacement of batteries, belts, hoses, and other fluids. To make this routine maintenance a "no-brainer," Generac uses advanced generator controls that include predictive algorithms to warn users when maintenance is required.

Sensor, Connection, and Circuit Board Failure
Another common cause of generator failure is deterioration of sensor connections caused by oxidation. This results in intermittent or false readings that may cause the generator to shut down. Generac has developed controls that make use of a sealed wiring harness to limit this oxidation. In addition, Generac sensors, which utilize a premium 4-20 ma signal, common in mission-critical process controls, are more accurate, less sensitive to corrosion, and resistant to electrical noise.

The current industry norm for generator controls includes multiple devices, non-sealed boards, and vibration-sensitive components. Because circuit-board design has a significant impact on generator system reliability, Generac uses an integrated approach. Instead of a collection of independent components, Generac combines multiple (or all of its) control functions into a single, secure, all-digital controller. This approach also eliminates the need for interconnected wiring which, in and of itself, increases reliability. Generac's surface-mounted controls are sealed inside an aluminum casing which minimizes vibration and provides environmental and electrical protection.

Fuel-Related Failures
Because of their lower capital cost, diesel-powered generators are the industry norm for applications larger than 150 kW. However, diesel comes with inherent reliability issues. For example, it may take up to 10 years for a typical generator application to exhaust its diesel fuel supply. If this fuel is not aggressively maintained, it becomes unreliable over time. The other significant problem is the risk of running out of fuel during an outage. When an area-wide power outage occurs, refueling the generator may be extremely difficult. To address these issues, Generac has developed two alternatives to the standard diesel approach.

Bi-Fuel - To minimize the amount of diesel that must be maintained on site, Generac offers bi-fuel engines (or generators) that run on a combination of 30% diesel fuel and 70% natural gas. This extends the run time of stored diesel by a factor of five and reduces the need for frequent refueling. The generator reverts automatically to 100% diesel operation in the unlikely event of concurrent electric and gas service interruption.

MPS - In most areas of the country, natural gas has proven to be reliable and it may be the best option for customers who don't wish to be burdened with diesel maintenance and a refueling contingency plan. To make this a realistic choice for the market, Generac has developed natural gas-powered generator solutions that are cost effective up to 300 kW. To accomplish this, Generac maximized the power density of automotive and industrial natural gas engines and applied its Modular Power System (MPS) paralleling technology. The result is a redundant, highly reliable natural gas solution with an infinite supply of good fuel.

Single-Point Failures (+1 Redundancy)
Though a single-engine generator can be made more reliable through good design, the potential for single-point of failure remains. Generac's flexible, cost-effective solution to this problem is modular paralleling systems. Parallel systems have always offered significant advantages for standby power generation, but these solutions traditionally have been limited to mission-critical applications and large-kilowatt projects. This is largely because of the constraints inherent in traditional paralleling solutions: cost, space, issues of single-source responsibility, and a significant level of complexity. To provide the benefits of parallel power generation while removing cost and complexity limitations, Generac developed its Modular Power System. MPS is a completely integrated, UL-listed power solution that utilizes an integrated digital controller and a paralleling switch mounted inside the generator connection box. This approach achieves the simplicity and cost efficiency of a single-engine solution while maintaining the redundancy, scalability, flexibility, and serviceability of a parallel system.

Generac natural gas-fueled MPS models are available up to 4500 kW. Diesel-fueled MPS units are available up to 9000 kW.

Total-Solution Approach to Reliability
In the world of power generation, Generac Power Systems is a true supplier of power solutions, not just a generator manufacturer. Generac enhances system reliability and leads the market by addressing all aspects of on-site power production. Please contact your local Generac dealer to learn more about the solutions Generac can provide for you.