Can the system be installed on existing generators?

Yes. The solution is designed for existing generators and can be retrofitted across different brands, models, and years without replacing the generator or controller.

How long does installation take and does it require downtime?

Typical installation takes around 1–2 hours per generator. Automatic start is usually disabled briefly during installation, but no extended downtime is required.

Does installation affect generator warranty?

No. The system is designed to be non-intrusive and operates independently from the generator controller, helping preserve existing warranties.

What generator parameters are monitored in real time?

The system monitors key parameters including mains availability, generator run status, fuel level, battery voltage, temperature, runtime, and test run events.

How does the system detect power failures and confirm generator start?

Power failures and generator output are detected using dedicated AC transducers, allowing immediate confirmation of generator start and operation during outages.

What alerts and notifications are available?

Alerts can be configured for power failures, generator start or failure to start, low fuel, battery issues, abnormal runtime, and connectivity status, delivered via email, SMS, WhatsApp, phone call, or API.

Does the system log runtime and test runs for compliance?

Yes. Generator runtime, start-stop events, and test runs are logged automatically and available for reporting, audits, and compliance purposes.

Can multiple generators across different sites be monitored from one dashboard?

Yes. Multiple generators across different locations can be monitored from a single cloud-based dashboard, including remote and cellular-connected sites.

How does the system help prevent generator failures?

By monitoring fuel usage, battery behaviour, temperature trends, and runtime patterns, the system helps identify early signs of degradation so maintenance can be planned proactively.

Remote Generator Monitoring System

Real-time monitoring of Diesel fuel level, runtime, battery health, power events, and test runs across all your generators brands and models with instant alerts and a central cloud dashboard.

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Real-Time Power Loss & Recovery Alerts

Monitor mains availability, generator status, and backup operation in real time

View all sites from a single central dashboard

Receive immediate alerts when mains power fails, generators start, or power is restored

Fuel Level Monitoring & Alerts

Track diesel fuel levels continuously

Receive instant alerts before low fuel causes shutdowns

Reduce risk of unexpected generator failure

Battery Health Monitoring

Detect weak batteries and charging issues early

Prevent generators from failing to start during emergencies

Improve system reliability and readiness

Runtime & Usage Tracking

Automatically log generator runtime and utilisation

Optimise maintenance scheduling

Support accurate billing and extend asset lifespan

Predictive Fault Detection

Identify abnormal fuel consumption patterns

Detect unusual runtime or electrical behaviour

Act before faults lead to downtime

Automated Test-Run Verification

Automatically verify scheduled generator test runs

Record time-stamped compliance logs

Simplify audits and regulatory reporting

Multi-Site Generator Dashboard

Manage generators across multiple sites or projects

Centralised visibility for teams and operators

Suitable for multi-customer or multi-location environments

Retrofit Installation on Existing Generators

Non-intrusive retrofit installation

No controller replacement required

Does not affect existing generator warranties

Instant Alerts & Historical Reporting

Receive alerts via Email, WhatsApp, SMS, or phone calls

Integrate with third-party platforms via REST API

Access full historical data for analysis and audits

Generator Monitoring System – Key Features

Construction & Infrastructure Contractors

Civil works, building projects, infrastructure sites, temporary power installations, mobile construction generators

Construction sites rely heavily on temporary and mobile generators to power critical operations. IoT Pro provides real-time visibility across multiple sites, ensuring generators run reliably during critical works while reducing fuel waste and unplanned stoppages.

Monitor generator status and fuel levels across all sites from one dashboard

Prevent mid-operation shutdowns due to low fuel or battery failure

Track runtime and usage patterns to reduce overuse and service costs

Receive instant alerts during power loss or generator failure

Eliminate reactive site visits through remote monitoring

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Generator Rental & Hire Companies

Generator rental fleets, temporary power hire, event power systems, standby generators for construction and industry

Rental companies must ensure generators operate correctly once deployed while protecting assets and revenue. IoT Pro enables full remote visibility of rented generators, improving uptime, billing accuracy, and fleet control.

Detect low fuel, misuse, or overload before failures occur

Track verified runtime hours to eliminate billing disputes

Reduce emergency call-outs with early fault detection

Monitor fleet performance across multiple rental sites

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Fuel Distribution & Energy Supply Companies

Diesel fuel suppliers, LPG distributors, refuelling contractors, energy service providers

Fuel suppliers depend on accurate consumption data to plan deliveries and maintain customer trust. IoT Pro accurately monitors generator fuel usage, enabling smarter delivery planning and proactive customer engagement.

Monitor real-time fuel consumption instead of estimating usage

Trigger automatic low-fuel alerts for timely refuelling

Reduce emergency shutdowns between scheduled deliveries

Enable data-driven upselling and service optimisation

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Facilities & Estate Management Companies

Commercial buildings, residential complexes, mixed-use developments, managed properties, critical facilities

Facility managers must guarantee generator readiness across multiple properties while proving compliance. IoT Pro provides a central view of all backup power assets, eliminating blind spots and manual checks.

Verify generator readiness before power outages occur

Automatically log test runs with time-stamped records

Monitor fuel and battery health between service visits

Reduce response times with instant outage alerts

Prove SLA and compliance performance to clients

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Manufacturing Plants & Industrial Sites

Electronics, pharmaceuticals, food & beverage production, printing, injection moulding, packaging, textiles, ceramics, heavy industry

Industrial operations depend on generators for backup power and critical processes. IoT Pro helps manufacturers prevent costly downtime by detecting generator degradation early and optimising maintenance.

Detect battery, alternator, or charging issues before emergency start failure

Monitor runtime and fuel usage trends to improve efficiency

Identify abnormal operating behaviour between service intervals

Automate runtime and test-run records for audits

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Data Centres & Telecom Operators

Data centres, telecom exchanges, network hubs, critical communication infrastructure

Data centres and telecom sites require absolute confidence in generator performance. IoT Pro provides independent verification that generators start and operate correctly during real outages, not just scheduled tests.

Confirm automatic generator start during real power failures

Maintain accurate logs for ISO 27001 and SLA compliance

Detect temperature, or runtime anomalies early

Enable faster escalation with real-time alerts

Gain full visibility without relying solely on third-party FM teams

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Hospitals & Healthcare Facilities

Hospitals, clinics, laboratories, pharmaceutical storage, medical facilities

Healthcare environments cannot tolerate generator failure. IoT Pro ensures backup generators are always ready, monitored, and compliant with strict healthcare regulations.

Prevent failed emergency starts due to battery or fuel issues

Automatically record test runs for compliance audits

Monitor multiple generators across departments and buildings

Receive immediate alerts during outages

Reduce risk through proactive fault detection

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Hotels & Large Retail Chains

Hotels, resorts, shopping centres, supermarkets, retail chains, hospitality groups

Hospitality and retail operations rely on generators to maintain guest experience and business continuity. IoT Pro ensures generators operate only when needed and alert teams instantly when issues arise.

Detect generator start failures during outages

Receive alerts during out-of-hours incidents

Verify test runs for insurance and brand audits

Monitor multiple sites from one central dashboard

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Public Utilities & Local Councils

Water pumping stations, substations, traffic systems, public infrastructure, municipal assets

Public sector organisations manage geographically dispersed generators with limited resources. IoT Pro enables proactive monitoring and accountability across critical public infrastructure.

Monitor remote generators without manual inspections

Receive instant fault alerts to speed service restoration

Maintain consistent runtime logs for reporting

Prevent missed refuelling and delayed maintenance

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Construction

Rental

Fuel Delivery

Facilities

Manufacturing

Data Centres

Healthcare

Retail

Government

Industries That Benefit from Generator Monitoring

Generator Monitoring Public Wiki

Explore the full Generator Monitoring system architecture, including data flow, monitored parameters, and integration components, in our Public Wiki.

Public Wiki

Generator Monitoring Solution Architecture

Connectivity & Data Security

Multi-Site Monitoring & Maintenance

Alerts, Logging & Compliance

The system supports a wide range of alerts, including power failure and recovery, generator start or failure to start, low fuel levels, battery voltage issues, abnormal runtime behaviour, and connectivity status. Alerts can be delivered via email, SMS, WhatsApp, automated phone calls, or REST API integration with third-party systems. This flexibility, configurability, and reliability is typically not offered by traditional BMS or bundled monitoring solutions.

Monitoring & Power Detection

The system monitors the most critical generator parameters in real time, including: • Generator running / stopped status • Mains power availability • Generator power output presence • Diesel fuel level • Battery voltage and charging behaviour • Engine temperature • Generator runtime and operating hours • Test runs and start/stop events These parameters provide a complete picture of generator readiness and performance.

IoT Pro uses AC-to-dry-contact transducers to detect power conditions. • One transducer monitors the external (mains) supply • A second transducer monitors the generator output Any power loss or generator start event is detected instantly and relayed through the IoT Pro system in real time, allowing immediate confirmation that the generator has started correctly during an outage via the alerting system.

Installation, Compatibility & Warranty

The system is designed specifically for existing generators. No new genset or controller replacement is required. IoT Pro incorporates: • An IoT Pro monitoring module • A capacitive fuel level sensor • A temperature sensor • Input and output interfaces connected to the generator battery and AC status This makes the solution ideal for brownfield installations and mixed generator fleets.

A typical installation takes 1–2 hours, depending on the generator model and technician familiarity. All information of how to perform the installation is available from the IoT Solutions Wiki.(https://wiki.iotsolutions.com.mt/doc/industrial-generator-management-1LKozcZnP2) During installation, automatic generator start is usually disabled temporarily. If a power outage occurs, technicians can manually start the generator safely. No extended downtime is required.

No. The IoT Pro generator monitoring solution is non-intrusive and does not affect generator warranty. Fuel level is measured using a separate capacitive sensor installed via an available inspection port. Battery voltage is monitored by working in parallel with extremely low current draw (below 50 µA). AC status is detected using external transducers, and the temperature sensor is installed in an existing engine block port.

Generator Monitoring Overview

A generator monitoring system provides real-time visibility of a generator’s operating condition, helping ensure it is ready to run when power fails. It monitors critical parameters such as power availability, generator status, fuel level, battery health, runtime, and alarms, and presents this data on a central dashboard with instant alerts. The IoT Pro Generator Monitoring System is a retrofit solution that can be installed on any generator brand, model, or year. It works independently from the generator controller, accurately monitoring the most critical aspects of generator performance without interfering with existing systems or affecting warranty.

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