Industry: Healthcare / Medical Office
Location: Longmont, Colorado
Service Provided: Generator Diagnostic, Gas Supply Analysis, Regulator Evaluation
Overview
A medical facility in Longmont was experiencing recurring generator start failures that had continued for several months. The unit would intermittently refuse to start, display overcrank errors, or crank slowly before shutting down. Previous visits addressed the regulator and gas pressure, but the issue continued to return.
Generator Source performed a deeper diagnostic and discovered the root cause that previous service attempts had not fully resolved.
The Challenge
The generator had a long history of start-related issues dating back to early in the year. Multiple symptoms were reported across several visits:
• Failure to start
• Overcrank errors
• Long crank times
• Low or inconsistent gas pressure
• Intermittent behavior that could not always be replicated
During the latest visit, the technician found the unit unable to start at all, raising concerns that the regulator adjustment completed a month earlier was not solving the underlying problem.
Another significant discovery was made on the rooftop. The generator shared a gas line with six to seven other pieces of equipment, creating competition for fuel supply and inconsistent inlet pressure during startup.
Our Assessment
The technician and supervisor performed a complete review of service history and onsite conditions to determine why multiple corrective actions had not resolved the problem.
Key Findings:
- Shared Gas Line
The generator was pulling from a gas line that also fed several other rooftop units. This caused inconsistent pressure and periods of starvation during cranking. - Regulator Instability
A secondary regulator installed earlier in the year improved performance temporarily, but pressure loss on the shared line caused recurring issues. - Historical Evidence of Fuel-Related Failures
Past reports noted slow cranking and improved performance after regulator adjustments, reinforcing fuel supply as the primary cause. - Intermittent Nature of the Problem
Because the building’s gas load changed throughout the day, the generator would fail unpredictably.
The Solution
Generator Source recommended the following corrective steps:
1. Immediate Diagnostic and Temporary Recovery
A senior technician was dispatched to assist with onsite adjustments and attempt to stabilize the unit for scheduled PM work.
2. Recommendation for a Dedicated Gas Line
To eliminate pressure competition, Generator Source advised the facility to have a dedicated gas line installed for the generator. This offers:
• Stable inlet pressure
• Faster, reliable starting
• Reduced overcrank events
• Manufacturer-aligned best practice for natural gas units
3. Regulator Verification and Long-Term Monitoring
After adjustments, the regulator would be monitored over the next several visits to confirm stable performance once gas supply issues were resolved.
The Result
With pressure issues identified and the root cause clearly documented, the facility now had:
• A clear explanation for years of intermittent start failures
• A recommended long-term fix: a dedicated fuel line
• Improved stability after immediate adjustments
• Confidence that the problem was supply-related, not generator failure
• A documented history for future technicians and facility staff
The generator was brought back online temporarily, and the facility began evaluating options for updating their gas infrastructure.
Why It Matters
Natural gas generators require consistent inlet pressure to start properly. Shared lines, high load demand, and undersized piping are some of the most common causes of:
• Start failures
• Overcrank alarms
• Extended cranking cycles
• False assumptions that the generator is failing mechanically
This case highlights how correct diagnostics can save significant cost by avoiding unnecessary parts replacement.
Experiencing hard starts or overcrank errors on your natural gas generator?
Generator Source provides full diagnostic services, fuel system evaluations, and long-term reliability solutions for commercial and industrial facilities.
Contact our service team to schedule a diagnostic inspection today.