Remote Generator Monitoring

With generators that are not monitored remotely, the fuel can run out and the set can stop even though it is running without problems, because nobody is tracking the fuel level; this is only noticed when someone visits the site. The risk is particularly high at unmanned facilities such as base stations.

Remote monitoring provides instant notification of conditions such as a low fuel level, a weak battery or the set not being in automatic mode. On construction sites, in telecom, in agricultural irrigation and across scattered branch networks, this prevents unnecessary service visits and unplanned outages.

How is the system set up?

There are three parts:

1. Controller: The brain of the set. It measures engine and alternator values and raises alarms. It needs a communication port (RS485, Ethernet, USB) or a built-in modem.
2. Connection: A GSM/4G modem, Ethernet or a satellite link on some remote sites. Inside a facility, a connection to the building management system (BMS) or SCADA via Modbus RTU/TCP or a similar protocol.
3. Interface: The controller manufacturer’s PC software, a web portal, a mobile app or the facility’s own system. Alarms arrive by SMS, email or app notification.

Many common controllers support these options directly or with an add-on module. Which option suits you depends on the connectivity available on site and how many sets are to be monitored.

What to monitor?

Value	Why it matters
Running status and mode	Is the set in auto? Has it been left in manual or off by mistake?
Alarms and faults	Shows why the set stopped, before anyone travels to site
Fuel level	The most critical value on remote sites; refuelling is planned around it
Battery voltage	A weak battery is one of the top reasons a set fails to start
Running hours	Sets the maintenance schedule
Oil pressure, coolant temperature	Engine health; trend tracking
Voltage, frequency, current, kW	What the load is, and whether the set is struggling
Mains status, ATS position	When did the outage happen, and did the set pick up the load?

Setting up alarms properly

The weakest link in remote monitoring is the alarm setup. If everything raises an alarm, nobody looks. If nothing raises an alarm, the system was installed for nothing.

• Warning versus fault: “Fuel at 30%” is a warning; “shut down on low oil pressure” is a fault. They can go to different people through different channels.
• Fuel threshold: Set it according to the refuelling time. If fuel takes a few days to arrive, keep the threshold correspondingly high.
• “Not in auto” alarm: One of the most useful alarms on site. After maintenance, the set gets left in manual.
• Who does it go to? Is the on-call list up to date? If the alarm goes to the phone of someone who has left the company, the system is not working.
• Theft warning: An abnormal drop in fuel over a short time can be a sign of fuel theft.

Inside a building or on a remote site?

The two scenarios are different. In a facility such as a hospital, shopping centre or factory, the generator is usually connected to the facility’s own building management system. The technical team monitors air conditioning, pumps and the generator on the same screen. Here an open protocol such as Modbus and a correct register list may be enough; an outside internet connection may not be needed.

On scattered sites such as telecom stations, irrigation pumps, construction sites or rental sets, each set sends data to the cloud through its own modem. Dozens of sets appear on a single map. The issues that matter here are cellular coverage, the cost of the data plan, fuel level and theft warnings. If coverage is weak, you need to try an external antenna or a different operator.

Data-driven maintenance

If running hours are visible remotely, maintenance is planned on actual use rather than the calendar. A coolant temperature that creeps up slowly over months can reveal a dirty radiator before it turns into a fault. For maintenance scope, see our scheduled maintenance page.

Outage report

A well set-up monitoring system tells a short story after every outage: what time the mains failed, how many seconds the set took to start, at what second the ATS transferred the load, how big the load was, when the mains returned, and how many minutes the set ran its cool-down. These records give concrete information to both the maintenance team and management. Repeated short outages, rising load or a lengthening start-up time get noticed before a serious fault.

Cyber security

A controller exposed to the internet is a door open to the internet.

• Change the default passwords.
• Where possible, use an encrypted connection (a VPN or the manufacturer’s secure cloud service). Do not expose the device directly to the open internet.
• Limit remote start/stop authority to a few people.
• Keep up with software and firmware updates.

Remote starting is also a health and safety issue. It must not be possible to start the set remotely while maintenance is being done on site. During maintenance, the set is switched to “off” and locked out.

Common mistakes on site

• The SIM card has expired. The system has not sent data for months, and nobody noticed.
• The antenna is inside the canopy. The metal canopy blocks the signal. The antenna must be mounted outside.
• The fuel sensor is not calibrated. 60% on screen, 20% in the tank.
• The alarm list has never been tested. At the first real alarm, no message reaches anyone.
• The data is there, but nobody looks. The portal is set up, but no one has been made responsible for it.

Checklist

• Does the controller support communication?
• What connection is available on site: GSM/4G, Ethernet, BMS?
• Is a fuel level sensor fitted and calibrated?
• Who receives warning and fault alarms, and through which channel?
• Is a “not in auto” alarm defined?
• Have the passwords been changed, and is the connection encrypted?
• Who has remote command authority?
• Is the alarm chain tested once a month?

Next step

Remote monitoring works best when it is planned together with the ATS and the generator controls. See what is an ATS and telecom generators. For your project, contact us.