How to Build a Custom Generator for Your Commercial Application

Selecting the right generator for an industrial or commercial application goes far beyond sizing your generator and selecting a fuel type. Depending on your location and your industry, your backup power system may also need to adhere to other, equally important specifications.

For homes and some smaller businesses, off-the-shelf gensets are sufficiently optimized for to be a better fit. However, a majority of industrial or commercial applications have specific electrical requirements and performance needs that can’t be met with an off-the-shelf generator.

How can you build a custom generator that’s perfectly tailored to your application and power needs? Let’s look at what generator customization really means, and how to choose the type of customization that’s right for you.

Accessories vs. Custom Configurations

There are two tiers of generator customization: generator accessories and custom configuration.

Generator Accessories

Generator distributors are authorized to customize a generator set with additions and add-ons that enhance or change a generator’s performance. Popular generator add-ons include:

• Trailers
• Standard enclosures
• Battery chargers
• Automatic transfer switches
• Additional fuel tanks
• Remote monitoring systems and control panels

Add-ons like these can change how well a generator functions to a certain degree, but these performance enhancements are limited because they do not change the inherent design of the generator.

This is important because generator distributors cannot make changes to a generator or inherent design due to restrictions from the manufacturer. Unauthorized changes to a generator void the manufacturer’s warranty, which could cost you a significant amount of money down the line if your generator fails or needs repairs.

Generator customization

Unlike add-ons, custom configuration of a generator means making changes to a generator’s overall design to meet particular power requirements, design, or performance demands. Popular custom configurations include:

• Changing the size or format of the generator base or enclosure
• Upgrading minor or major components
• Increasing or decreasing power output
• Tailoring power connections
• Enabling compatibility with other devices or systems
• Upgrading the cooling system

Generally, distributors cannot make these types of customizations because they require changing how a generator is designed or built and will not be able to re-certify the generator after said modifications. Only the original manufacturer of a generator is authorized to make changes to its design without negatively affecting warranty coverage and safety.

Why Choose Custom Generator Configuration?

Most residential generators work perfectly well without any custom configuration. However, most commercial or industrial applications require some level of customization to perform as needed. These are just some of the reasons why custom configuration might be right for your application.

	Upgrade Requirements Many people choose to custom configure a generator because of their desire to “upgrade” its performance. For instance, certain applications might require a generator to operate with a voltage selector switch that would allow to effortlessly change the voltage output of the generator.
	Budget Limitations For certain industrial or commercial applications, it can be difficult to find a pre-built generator that meets certain power requirements without breaking the bank. By customizing a generator, you can save money by removing unnecessary components, and enhancing performance in more important areas.
	Industry Demands Many industries — including oil and gas, farming and poultry, construction, and manufacturing — need specific customization. A generator for an oil rig, for instance, may need heavy-duty upgrades to protect the generator from the elements. On the other hand, construction crews might need a generator that’s designed for mobility and compatibility with equipment they already have on-site.
	Performance Demands For applications that have highly variable electrical loads or require the synchronization of generators running simultaneously, custom configuration is often the most cost-effective way to go. Many performance demands will require intrinsic changes to the control system as well as permanent upgrades to the other main components.
	Installation Site Requirements Depending on the location of a generator, certain changes might need to be made to its inherent design to operate effectively. This might mean changing the format of a generator to fit into a smaller area, or changing specific components to withstand corrosion due to inclement weather.

How to Customize Your Generator

Custom generator configuration requires specialized knowledge and experience. This is why it’s important to work with a skilled team of engineers and power experts when making changes to your generator. They can walk you through the process of custom configuring your generator; suggest specific changes that will meet your unique power needs; and ensure that these customizations do not negatively impact your generator’s performance.

At General Power, we manufacture a line of highly customizable generators. Our in-house team of engineers can customize these generators with engines from John Deere, Kohler and Perkins, alternators from Stamford and Leroy Somer, controls from Deep Sea Electronics and ComAp, and many kinds of enclosures, silencers and accessories. We can meet your specific power needs and application demands.

If you need a generator that’s customized for a commercial or industrial application, contact the power experts at General Power by calling us at 1-888-819-5646 or requesting a free quote.