Small 3-Phase Genset Loadbank Testing

The manufacturers recommend a minimum of 30% (or atlest 25%) load to run the genset, failing to fulfill this requtrement; initialy the exhaust gas colour changes from light grey to dark smoke, in the long term dammage to primemover can occour.

Thre is not much sence in runing the generator to 100-110% load on a regular basis it can be left for special occasions.

Check out manufacturers recommendations for generator loading and comply with the instructions.

During low load condition, you may provide the old concept of running the unit with a load test bank by installing/fabricating the following:

1. Fabticate load test bank made of steel plate or other materials and install insulator

2. Install bus bar with wench (manually operated) to control the loading of genset

3. Mixed salt and water (approx. 1/2 sack of salt for every 5cu.m of water) - excessive boiling indicate to much sal content.

4. Install temperature sensor if required

Please insure that safety will be considered in doing this task .

You could also use an electrical heating as load for your gen set. Mostly they have a power around 3 or 4 kW and they are not expensive. Buy 3 or 4 pieces and connect them equally distributed on your gen set.

Am interested in this question but ur not specific to what U want. Let me get ur point.

Dickson

Ok, so I have contacted the supplier/manufacturer who advise to apply an initial load of 30 to 50%, run for around 1hour. Then apply load around 75% and run for another hour. Finally, apply load at 100% and run for another hour, and then reduce the load following the same pattern as it was applied. I am led to believe the main purpose is to have the diesel engine clear contaminants/unburnt fuel. However, if there is significant glazing it may take more time to clear from the engine.

This genset runs 24hours a day and feeds 3 motors running pumps. The system monitors water levels - set point of say 50m, when water reaches 55m pumps start until the water drops to 45m when pumps stop. The pumps vary in run time from running every hour to running once a day. Loading works out around 15% for each pump so that the genset never runs more than 50%.

My cautious side says to not run the genset under full load for more than a few hours at most. The diesel fitter wants to run the genset under full load for up to 24hours. The supplier/manufacturer recommends not more than 2hours.

Extra question/s - what is the likelihood of damage to the alternator if running at or above 100% load for more than a few hours? what sort of damage may occur? If glazing has occured what sort of time at full load may remedy/reduce the situation?