Installing an industrial generator is one of the most important investments you can make in your facility’s resilience. But even the highest-quality equipment can become unreliable—or unsafe—if the installation is handled poorly. A successful emergency power system is built on careful planning, engineering, and execution, not just the equipment itself.
With more than 50 years of experience, Generator Source has seen the costly mistakes that businesses make when installing commercial and industrial generators. Below are the five most common errors we encounter in Colorado, Florida, Texas, and beyond, and how a professional approach prevents them.
Mistake #1: Skipping a True Site Assessment
The most expensive errors often happen before the generator even arrives. Rushing the assessment and engineering phase is the top cause of long-term issues.
An inexperienced installer might rely on breaker counts or simple estimates. A professional load calculation goes much deeper. It reviews schematics, separates life-safety systems from optional loads, and accounts for heavy inrush currents from HVAC, elevators, or other large motors. Failing here means the generator may be undersized and destined to fail in an outage.
Placement is equally critical. Generators installed too close to windows or doors may violate NFPA codes, while those sited without considering local noise ordinances can lead to fines or legal disputes. A professional plan ensures compliance, safe access for cranes and fuel trucks, and efficient routing to electrical and fuel services.
Mistake #2: Underestimating the Move
Industrial generators can weigh tens of thousands of pounds, often as much as a school bus. Moving them into position is a project of its own, and underestimating the logistics is a common mistake.
The solution is professional rigging, a crane sized for the job, and project management that coordinates every step. Without it, projects stall when a crane can’t reach over an obstacle or a truck can’t make the final turn. A pre-lift site walk and detailed logistics planning ensure the generator is set precisely on its engineered pad, ready for anchoring.
Mistake #3: Cutting Corners on Electrical Work
The electrical connection is the most demanding and dangerous phase of installation. This work requires licensed professionals who specialize in high-amperage power systems, not just general electricians.
The Automatic Transfer Switch (ATS) is the centerpiece. If it’s installed improperly, the load may fail to transfer or, worse, the generator may backfeed the utility grid, putting line workers at risk. Every cable must be cleaned, torqued, and tested to exact specifications. Even one loose low-voltage control wire can stop a generator from starting in an outage.
Mistake #4: Overlooking Fuel and Exhaust Systems
A generator is an engine, and it needs two lifelines: fuel and exhaust. Overlooking either can lead to failure or create safety hazards.
- Fuel: Diesel systems must use properly sized lines and pumps capable of maintaining flow at full load. Natural gas units require a dedicated, licensed gas line with adequate pressure and volume.
- Exhaust: Poorly designed exhaust can create dangerous backpressure, reducing performance and shortening engine life. Worse, leaks can release carbon monoxide near occupied spaces. Professional installations use insulated, industrial-grade piping engineered to handle vibration and heat.
Mistake #5: Skipping a Real Load Test
One of the most common oversights is inadequate commissioning. Too many projects end with a simple no-load startup, which proves only that the engine can turn on.
The only true test is a load bank. By applying controlled electrical load for several hours, the generator is pushed to its rated capacity. This process proves cooling systems are sufficient, validates performance under stress, and seats piston rings in new diesel engines. Without it, the system’s reliability is left to chance, at the exact moment you can’t afford failure.
Trusted Generator Installations in Colorado, Florida, Texas, and Beyond
A reliable emergency power system is more than just equipment, it’s the product of a professional installation that anticipates challenges before they happen. From site assessments to rigging, electrical integration, fuel systems, and final testing, Generator Source delivers safe, compliant, and dependable installations for commercial and industrial clients.
Whether you’re in Denver, Jacksonville, Pensacola, Austin, or the surrounding regions, our team provides the expertise to get your project right the first time.
Learn more about generator installation services or contact Generator Source today for a professional assessment of your facility’s needs.