Shop Floor Talk  

Go Back   Shop Floor Talk > Welding and Metalworking Forums > Equipment, Suppliers and OEM's

SFT Search:   
Reply
 
Thread Tools Display Modes
  #1  
Old 10-19-2011, 10:39 AM
Walker's Avatar
Walker Walker is offline
Standard of Excellence
 
Join Date: Aug 2004
Location: Cave Creek AZ
Posts: 2,529
Default How to creat a load bank?

I have decided to keep my big diesel generator and run it up to my cabin in the spring. One problem is that it is a 15Kw generator and I just can't come up with tat kind of demand for it. So I want to come up with a load bank that I can run on it from time to time to keep the diesel engine happy. Aside from a stack of microwave ovens and hairdryers, how can I come up with a goodly amount of kilowatts to make a load bank? Oh, and cheaply, as always
__________________
Walker
Chief slag chipper and floor sweeper, Ironwood Artistic
Reply With Quote
  #2  
Old 10-19-2011, 10:44 AM
moe1942's Avatar
moe1942 moe1942 is offline
Voice of Experience
 
Join Date: Jun 2004
Location: Alexandria, Louisiana
Posts: 10,157
Default

Three electric range cooktops should do it. They suck up about 5KW each at full burner. Take the burners and controls out, put them all in a suitable housing and hook them in series parallel. Don't forget to install a large fan..

Start turning burners on and check draw with an amp probe.. Poor(cheap) mans portable load bank..
__________________
Don't pick a fight with an old man. If he is too old to fight, he'll just kill you... John Steinbeck

"If we ever forget that we're one nation under God, then we will
be a nation gone under". ~Ronald Reagan

We should have picked our own cotton...

I love my women hot and my beer ice cold..
Reply With Quote
  #3  
Old 10-19-2011, 07:47 PM
mcostello's Avatar
mcostello mcostello is offline
Member
 
Join Date: Dec 2007
Location: lancaster,ohio
Posts: 235
Default

Iffn you do this in the winter the heat could be welcome.
Reply With Quote
  #4  
Old 10-19-2011, 07:57 PM
milomilo's Avatar
milomilo milomilo is offline
Auction Addict
 
Join Date: May 2010
Location: Wheatland, Wyoming
Posts: 6,330
Default

Why make a load bank to run it on occasionally? The generator will do fine with a small load as well as a maximum load. I run mine every spring and fall for 15 minutes to keep the engine lubed up and I just use a portable fan. It doesn't take much to keep the generator operational and a small load will make the engine push a little.
__________________
Chris

The best way to find out if you can trust somebody is to trust them. Ernest Hemingway
Reply With Quote
  #5  
Old 10-19-2011, 08:50 PM
terry lingle's Avatar
terry lingle terry lingle is offline
Something's Fishy ...
 
Join Date: Aug 2004
Location: Birch Island, BC, Canada
Posts: 3,277
Default

You want 10 -12 KW load on it after it has warmed enough to see the temp gauge move up until the temperature has stabilized.
This load will keep the rings properly seated and bring the generator core up to temperature to keep it dry.
__________________
Life beats the alternative hands down.
Reply With Quote
  #6  
Old 10-19-2011, 08:54 PM
terry lingle's Avatar
terry lingle terry lingle is offline
Something's Fishy ...
 
Join Date: Aug 2004
Location: Birch Island, BC, Canada
Posts: 3,277
Default

I use oven elements for a load bank and wire them through a load center.
In your case you could use spare slots in the cabin panel and as stated run them for heat. you could also use 240 volt baseboard heaters to distribute the heat around the cabin
__________________
Life beats the alternative hands down.
Reply With Quote
  #7  
Old 10-19-2011, 09:50 PM
Walker's Avatar
Walker Walker is offline
Standard of Excellence
 
Join Date: Aug 2004
Location: Cave Creek AZ
Posts: 2,529
Default

It is my understanding that with a diesel engine you don't want it to run unloaded all the time due to a problem called wet stacking. This is a build up of carbon in the cylinders and if not burned off by loading up the engine can cause operational issues.
This is the Wiki page on it. "Wet stacking is a condition in diesel engines in which not all the fuel is burned and passes on into the exhaust side of the turbocharger and on into the exhaust system. The word "stacking" comes from the term "stack" for exhaust pipe or chimney stack. The oily exhaust pipe is therefore a "wet stack".

In diesel generators, it is usually because the diesel engine is running at only a small percentage of its capacity.

It is detectable when there is a black ooze around exhaust pipe connections and around the turbocharger. Continuous black exhaust from the stack when under a constant load is also an indication that all the fuel is not being burned.
__________________
Walker
Chief slag chipper and floor sweeper, Ironwood Artistic
Reply With Quote
  #8  
Old 10-19-2011, 10:08 PM
milomilo's Avatar
milomilo milomilo is offline
Auction Addict
 
Join Date: May 2010
Location: Wheatland, Wyoming
Posts: 6,330
Default

Quote:
Originally Posted by Walker View Post
It is my understanding that with a diesel engine you don't want it to run unloaded all the time due to a problem called wet stacking. This is a build up of carbon in the cylinders and if not burned off by loading up the engine can cause operational issues.
This is the Wiki page on it. "Wet stacking is a condition in diesel engines in which not all the fuel is burned and passes on into the exhaust side of the turbocharger and on into the exhaust system. The word "stacking" comes from the term "stack" for exhaust pipe or chimney stack. The oily exhaust pipe is therefore a "wet stack".

In diesel generators, it is usually because the diesel engine is running at only a small percentage of its capacity.

It is detectable when there is a black ooze around exhaust pipe connections and around the turbocharger. Continuous black exhaust from the stack when under a constant load is also an indication that all the fuel is not being burned.
My generator is gas. I wasn't aware of this condition on diesel generators.
__________________
Chris

The best way to find out if you can trust somebody is to trust them. Ernest Hemingway
Reply With Quote
  #9  
Old 10-19-2011, 10:42 PM
terry lingle's Avatar
terry lingle terry lingle is offline
Something's Fishy ...
 
Join Date: Aug 2004
Location: Birch Island, BC, Canada
Posts: 3,277
Default

Part of my last post vanished into the aether
You want 10 -12 kw load for proper ring seating. This prevents wet stacking.
the procedure is to start the unit and run until the temp gauge starts to come up then put on the load bank and run at least 1/2 hour to get the engine temperature stabilized. This load run will also warm the generator and drive out any moisture in it.

I use oven elements or baseboard heaters through the load center for fixed applications like this. to add load just switch on a breaker to an element outside the cabin if you do not want the heat or a baseboard inside if you do want the heat
__________________
Life beats the alternative hands down.
Reply With Quote
  #10  
Old 10-20-2011, 10:28 AM
Sberry's Avatar
Sberry Sberry is offline
GOD of Strawberries!!!
 
Join Date: Jul 2004
Posts: 3,609
Default

50A range, turn it all on high. Oven to broil.
__________________
urkafarms.com
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Web Search:
clyde@m2texas.net
clyde@m2texas.net
george@shopfloortalk.com bob@shopfloortalk.com

All times are GMT -5. The time now is 01:55 AM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2014, vBulletin Solutions, Inc.