Generator Load Bank questions

[RiverDave]

So this sign truck thing continues.. LOL. The generator is effectively sitting at zero % power usage even with the sign and two AC's running and equipment (processors and laptop).

Because it will start to "wet stack". I am looking for a small load bank that I can hopefully put into the electronics cabinet or one of the cabinets below.

I'm not educated on this stuff but the one that I have found so far with my limited searching is the Simplex Swift-E.

Is there something small I can use to just get this generator to the point where it won't wet stack?

Here's what I found and I'm looking for something even smaller if I can get it?

 

[RiverDave]

Simplex® | Small Portable Load Banks

Simplex makes small portable load banks.

www.simplexdirect.com

The swift-e is the one that fits my bill I believe

RD

 

[DaveH]

Gen-Tech here in Vegas has various size load banks for testing. Not that you want to drive all this way, but if it comes to it here is an option for you.

also, why such a big generator?

 

[The Chicken]

What are the actual loads in watts?
What size is the generator?
If the loads aren't crazy, maybe you could put some batteries and an inverter onboard, and have the inverter call for the generator only when the batteries are low, and load the genset more but for shorter times, saving fuel and genset wear and tear?

 

[hallett21]

Gen-Tech here in Vegas has various size load banks for testing. Not that you want to drive all this way, but if it comes to it here is an option for you.

also, why such a big generator?

I think he planned on making it a support vehicle for events as well.

 

[DaveH]

I think he planned on making it a support vehicle for events as well.

well then seems like a small genset to support the realistic load of the truck, wired to a x-fer switch, then run the big daddy when needed. very uneconomical the way its setup. like using a jackhammer to crack an egg.

 

[Waterjunky]

well then seems like a small genset to support the realistic load of the truck, wired to a x-fer switch, then run the big daddy when needed. very uneconomical the way its setup. like using a jackhammer to crack an egg.

This.......

 

[Mandelon]

Wet stacking is a condition in diesel engines in which unburned fuel passes on into the exhaust system.[1] The word "stacking" comes from the term "stack" for exhaust pipe or chimney stack. The oily exhaust pipe is therefore a "wet stack".

This condition can have several causes. The most common cause is idling the engine for long intervals, which does not generate enough heat in the cylinder for a complete burn. "Idling" may be running at full rated operating speed, but with very little load applied. Another is excessive fueling. That may be caused by weak or leaky injectors, fuel settings turned up too high or over fueling for the given rpms. Cold weather running or other causes that prevent the engine from reaching proper operating temperature can cause a buildup of fuel due to incomplete burn that can result in 'wet stacking'.[2][3] In diesel generators, it is usually because the diesel engine is running at only a small percentage of its rated output. For efficient combustion, a diesel engine should not be run under at least 60 percent of its rated power output.[4]

Wet stacking is detectable by the presence of a black ooze around the exhaust manifold, piping and turbocharger, if fitted. It can be mistaken for lubricating oil in some cases, but it consists of the "heavy ends" of the diesel fuel which do not burn when combustion temperature is too low. The heavier, more oily components of diesel fuel contain more stored energy than a comparable quantity of gasoline, but diesel requires an adequate loading of the engine in order to keep combustion temperature high enough to make use of it. Often, one can hear a slight miss in the engine due to fuel buildup. When the engine is first placed under a load after long periods of idling and wet stacking, it may blow some black exhaust out as it burns that excess fuel off. Continuous black exhaust from the stack when under a constant load is also an indication that some of the fuel is not being burned.[5] Additionally, wet stacking can result in a build up of diesel fuel in the engine which does not combust due to the low temperature in the engine. This results in a reduced fuel economy. This fuel leaks through the cylinders and dilutes the engine oil. If not frequently changed, this diluted oil can lead to increased wear on the cylinder and premature engine failure.[6]

 

[Mandelon]

Can you upgrade the alternator to put out more juice....enough to power the screens n bits while the engine is on? Seems like your generator is overkill for a portion of your needs.

 

[bilz]

Wet stacking is a condition in diesel engines in which unburned fuel passes on into the exhaust system.[1] The word "stacking" comes from the term "stack" for exhaust pipe or chimney stack. The oily exhaust pipe is therefore a "wet stack".

This condition can have several causes. The most common cause is idling the engine for long intervals, which does not generate enough heat in the cylinder for a complete burn. "Idling" may be running at full rated operating speed, but with very little load applied. Another is excessive fueling. That may be caused by weak or leaky injectors, fuel settings turned up too high or over fueling for the given rpms. Cold weather running or other causes that prevent the engine from reaching proper operating temperature can cause a buildup of fuel due to incomplete burn that can result in 'wet stacking'.[2][3] In diesel generators, it is usually because the diesel engine is running at only a small percentage of its rated output. For efficient combustion, a diesel engine should not be run under at least 60 percent of its rated power output.[4]

Wet stacking is detectable by the presence of a black ooze around the exhaust manifold, piping and turbocharger, if fitted. It can be mistaken for lubricating oil in some cases, but it consists of the "heavy ends" of the diesel fuel which do not burn when combustion temperature is too low. The heavier, more oily components of diesel fuel contain more stored energy than a comparable quantity of gasoline, but diesel requires an adequate loading of the engine in order to keep combustion temperature high enough to make use of it. Often, one can hear a slight miss in the engine due to fuel buildup. When the engine is first placed under a load after long periods of idling and wet stacking, it may blow some black exhaust out as it burns that excess fuel off. Continuous black exhaust from the stack when under a constant load is also an indication that some of the fuel is not being burned.[5] Additionally, wet stacking can result in a build up of diesel fuel in the engine which does not combust due to the low temperature in the engine. This results in a reduced fuel economy. This fuel leaks through the cylinders and dilutes the engine oil. If not frequently changed, this diluted oil can lead to increased wear on the cylinder and premature engine failure.[6]

I was just going to look that up, thanks!

 

[lbhsbz]

So this sign truck thing continues.. LOL. The generator is effectively sitting at zero % power usage even with the sign and two AC's running and equipment (processors and laptop).

Because it will start to "wet stack". I am looking for a small load bank that I can hopefully put into the electronics cabinet or one of the cabinets below.

I'm not educated on this stuff but the one that I have found so far with my limited searching is the Simplex Swift-E.

Is there something small I can use to just get this generator to the point where it won't wet stack?

Here's what I found and I'm looking for something even smaller if I can get it?

That's stupid. Get a smaller genset more suited to the loads you're using it for. Adding a load bank is simply a waste of fuel and wear and tear on equipment.

 

[Sharky]

Watch e-bay for an old, Onan 300-608 load bank. Or, a 420-385. They pop up from time to time.

They look like this.

 

[hallett21]

@RiverDave figure out a way to offer EV charging lol

 

[DaveH]

That's stupid. Get a smaller genset more suited to the loads you're using it for. Adding a load bank is simply a waste of fuel and wear and tear on equipment.

x100

all that a load bank will do is put a ton of heat into the vehicle. where do you think all that wasted energy goes?

 

[RIVERBORN]

Just get a little harbor freighter, run the shit out of it, replace when necessary.

 

[DaveH]

put in boating terms, it would be like have a turbo 1350 running at idle all day, then adding drag chutes in the water so as to load the engine more but not go any faster,

 

[TimeBandit]

@The Chicken to the white courtesy telephone please.

 

[hallett21]

@The Chicken to the white courtesy telephone please.

He’s already here lol

 

[Joe mama]

This is one of those cases where bigger isn’t better.
Then again it’s better to be looking at it than looking for it.

 

[Your ad here]

Who diagnosed the "problem"? It doesn't make sense to me. I suspect there is a circuit board or setting problem. Does produce any electrical power?

 

[hallett21]

Trying to think of a justifiable load you can add to run with everything.

My guess is this is all hardwired and Dave doesn’t want to re wire stuff and deal with transfer switches etc.

 

[hallett21]

Who diagnosed the "problem"? It doesn't make sense to me. I suspect there is a circuit board or setting problem. Does produce any electrical power?

It’s generating power but his load is too small. I’m sure he’s under 10% load.

 

[Joe mama]

It’s generating power but his load is too small. I’m sure he’s under 10% load.

Sounds like a personal problem.

 

[Your ad here]

put in boating terms, it would be like have a turbo 1350 running at idle all day, then adding drag chutes in the water so as to load the engine more but not go any faster,

Not really. Generators have to run at 1800 rpm. Some do have an idle down feature when no load is applied. At 1800 rpm and no load it is creating enough heat to not have immediate problems. When you add a load it will cause the engine to work harder to maintain 1800 rpm and it will create enough heat to burn off whatever it needs to.

 

[Your ad here]

It’s generating power but his load is too small. I’m sure he’s under 10% load.

If its generating power then what's the problem?

 

[hallett21]

If its generating power then what's the problem?

It won’t rev enough so it’s building up shit in the exhaust. Or could potentially.

 

[Your ad here]

It won’t rev enough so it’s building up shit in the exhaust. Or could potentially.

Is it making power and he's worried about wet stacking? The 0% usage in his first post is confusing. Sound like it's not making power because it doesn't sense a load.

 

[hallett21]

Is it making power and he's worried about wet stacking? The 0% usage in his first post is confusing. Sound like it's not making power because it doesn't sense a load.

“Effectively zero”

 

[DaveH]

Not really. Generators have to run at 1800 rpm. Some do have an idle down feature when no load is applied. At 1800 rpm and no load it is creating enough heat to not have immediate problems. When you add a load it will cause the engine to work harder to maintain 1800 rpm and it will create enough heat to burn off whatever it needs to.

he must not be having any issues then.

 

[monkeyswrench]

I like the battery and inverter deal...then you could set it up to run later and not have the diesel drone.

Or add some big ass searchlight on the truck...but only useful at night

 

[Your ad here]

he must not be having any issues then.

The original post is confusing. I'm now thinking everything works and its producing power but he's worries about wet stacking because the lack of load? FWIW I see diesel generators run year round powering job site trailers and never heard of one having problems with wet stacking. I have one with 10,000 hours and no problems. The exhaust pipe is sooty but not worried about it.
RD could put an RV plug on it and every 100 hours plug his RV in it and run all the stuff in the RV to create a heavy load so it makes some heat. Run the ACs, dryer, all lights, stereo, ect.

 

[rrrr]

Tell me the kW rating and I can offer some suggestions for a load to stress the genset adequately.

@RiverDave

 

[Sharky]

Not really. Generators have to run at 1800 rpm. .

Unless it's a Generac. We used to call them Gen-a-racket because they ran at 3600 RPM.

Onan & Honda were smart enough to add 2 more poles in the alternator side (AC) and cut engine speed (noise). Onan was even smarter and added a separate set of poles just for DC generation. That is what powered the ignition & control board on an Onan. You only needed a 12V battery to run the starter on an Onan. That is all the 12V battery does. The separate DC generator takes over to power ignition & board.

Naturally, they cost more.

 

[bonesfab]

@RiverDave figure out a way to offer EV charging lol

Should have bought an electric F-1fiddy..

 

[lbhsbz]

@RiverDave figure out a way to offer EV charging lol

Hook up a trailer with a cold plunge and a sauna…that should provide adequate load lol

 

[Nordie]

Hook up a trailer with a cold plunge and a sauna…that should provide adequate load lol

This mixed with a mobile ev charger mentioned above and RD is sitting on a gold mine. Play a movie while charging your tesla while doing a cold plunge.

 

[WTMFA]

This is what I do for a living. We have about 14 generators that are used to power the set while filming out on location. There is a load bank back at the shop that we use on occasion for testing and "blowing out" the genny when it's had minimal loads for long periods of time. All that being said, I think you're prematurely worrying about this. "If" the genny is used on a regular basis and is almost constantly under very low loads you would be fine using something to generate a heavy load once a year.
We have gennys that have mechanical fuel injection (way less efficient than electronic fuel injection) that have well over 10k hrs on them and at the most we've only ever load banked them once a year, and that would be on a genny that works on a regular basis out in the field under low load conditions.
You've got my number if you want to discuss in further detail

 

[Lunatic Fringe]

Maybe install a large Tesla coil on the roof.
It'll draw attention and kill off mosquitoes.

 

[DILLIGAF]

Maybe install a large Tesla coil on the roof.
It'll draw attention and kill off mosquitoes. View attachment 1433052

I dont understand but laughed anyhow. Any other suggestions?

 

[Lunatic Fringe]

I dont understand but laughed anyhow. Any other suggestions?

Nikola Tesla, not the car. (They don't have coils)

You may have to Google Nikola Tesla

 

[rrrr]

Unless it's a Generac. We used to call them Gen-a-racket because they ran at 3600 RPM.

Onan & Honda were smart enough to add 2 more poles in the alternator side (AC) and cut engine speed (noise). Onan was even smarter and added a separate set of poles just for DC generation. That is what powered the ignition & control board on an Onan. You only needed a 12V battery to run the starter on an Onan. That is all the 12V battery does. The separate DC generator takes over to power ignition & board.

Naturally, they cost more.

Good info. Generator (they're actually alternators) frequency is dependent on the number of rotor poles and stator configuration. The magnetic fields produced by the poles and the RPM determine the frequency of the output. Voltage is produced by those magnetic fields, regulated by varying a smaller voltage on the exciter assembly located on the end of the rotor.

I copied this because it's easier than texting it:

To produce 60 Hz power, engine driven generators will operate at 1800 rpm using a 4-pole generator. Lightweight, portable or residential generators may operate at 3600 rpm with a 2-pole generator. Larger generator sets may run at 1200 rpm (6pole) or 900 rpm (8-pole) or 720 rpm (10pole). (50 Hz is similar but 3,000 rpm for 2-pole, 1500 rpm for 4-pole, 1000 rpm for 6-pole etc.)

I worked in a few older (like 1950-1960s) facilities that had 900 RPM gensets. They were huge compared to their power output. Modern engine and alternator technology has greatly improved that.

 

[Blackmagic94]

well then seems like a small genset to support the realistic load of the truck, wired to a x-fer switch, then run the big daddy when needed. very uneconomical the way its setup. like using a jackhammer to crack an egg.

He is using .4-.5 gph. Not really agreeing with the uneconomical way lol

 

[Blackmagic94]

Who diagnosed the "problem"? It doesn't make sense to me. I suspect there is a circuit board or setting problem. Does produce any electrical power?

It does. He shows a max of 27% of 10,000 watts then the gauge goes to zero on load use. I believe the load gauge is wrong as it’s impossible to have zero load while two ac units and the other accessories are running. 2700 watts sounds very realistic to me but is still below the 7500-8000 that is recommended for long term use to avoid wet stacking. Hence my suggestion on a load board if he doesn’t want to add more power demand by other means.

 

[Blackmagic94]

Trying to think of a justifiable load you can add to run with everything.

My guess is this is all hardwired and Dave doesn’t want to re wire stuff and deal with transfer switches etc.

My suggestion was a 220 volt garage heater to blow through 5000 extra watts. Cheapest fix for 189 bucks. But your gonna be blowing hot ass air straight up the whole time

Maybe a third ac unit that was bigger to blow cold air off to the side where people stand at events. Get a 24,000 btu unit so it draws some power

 

[rrrr]

Trying to think of a justifiable load you can add to run with everything.

My guess is this is all hardwired and Dave doesn’t want to re wire stuff and deal with transfer switches etc.

My suggestion was a 220 volt garage heater to blow through 5000 extra watts. Cheapest fix for 189 bucks. But your gonna be blowing hot ass air straight up the whole time

Maybe a third ac unit that was bigger to blow cold air off to the side where people stand at events. Get a 24,000 btu unit so it draws some power

I hadn't thought about how it's power distribution is setup. I guess it's impractical to temporarily connect a significant load to it.

 

[WTR&PWR]

@RiverDave figure out a way to offer EV charging lol

I’m thinking the same thing. Put a 240V/50A plug on it and run a banner in the screen “free Tesla charging”. It’ll make a commotion and people will head to it. It will be its own advertising.

 

[n2otoofast4u]

Ray Charles saw this coming. You can power a city with the gen, but a 9v from your smoke detector will power it. Add a battery bank with an auto charge crossover, or go to Harbor Freight and buy a wannabe Honda that will work just fine.

 

[oldman]

Nikola Tesla, not the car. (They don't have coils)

You may have to Google Nikola Tesla

tesla coils and Jacob ladders are just cool toys to build.

Halloween is coming up.

OFFF TO THE LAB I GO.

 

[bilz]

I must have missed the different prop suggestion.

 

[HTTP404]

Throw some of these on there and just charge them with the generator as needed.

Industrial

For all of your machinery needs, BigBattery has the highest quality lithium-ion industrial batteries. Your vehicle will gain power and hours with less weight.

bigbattery.com