27000 Watt Load Complete Build!
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- čas přidán 16. 07. 2024
- 27kW load built from scratch, see the entire process! To learn electronics in a very different and effective way, and gain access to Mr Carlson's personal designs and inventions, visit the Mr Carlson's Lab Patreon page here: / mrcarlsonslab
#restoration #electronics #repairing - Věda a technologie
To learn electronics in a very different and effective way, and gain access to Mr Carlson's personal designs and inventions, visit the Mr Carlson's Lab Patreon page here: www.patreon.com/MrCarlsonsLab
Are you familiar with Armory Lovins at Rocky Mountain Institute and Bill Mollison of Permaculture fame ?
Should have just done a voiceover when gen was running.
HAPPY EASTER TO YOU AND YOUR FAMILY MR CARLSON. ⚘⚘⚘⚘
27000 watts- sounds good
FYI, get yourself some centre drills instead of small drills. The stubbier length for the start portion makes them a heck of a lot stouter than small sizes of drill making them perfect for starting holes. If you're lucky, you can even find them paired up for common dimensions. And yes, they do make them in small sizes. I've even seen them with 1mm starter drills paired up for a 3 or 4mm hole. Worth having a few around. Bonus: easy to sharpen, the flutes are simpler in design and they come with two ends. So you have multiple uses out of a single centre drill vs a drill bit which eventually runs out depending on how lucky you are when it breaks.
How GREAT would it be with Mr. Carlson's Lab as your next door neighbor? Just think going out on your porch in the morning to have a cup of Coffee/Tea and look over to your neighbor and just think, Will this be the day?" and his house lifts off with the secret Anti-Gravity drive with a barely audible hummmmmm. and see it shrink into the distance.
As long as he comes back like Dorothy did wer good.
Haha!
🤣
Great Scott!
It’s like “ Back to the Future “ 😂I love it
I love these videos that are not just receiver restorations! Thank you Mr. Carlson!
Ah yes, the man with the fan with the plan.
Let's hope this fan blade does not break off its motor to go bouncing around the room, at speed.
But was he in a pan?!?!?
This is true DIY. This is rarely seen in modern times.
Hopefully this can inspire future generations.
Agree
Check out photonicinduction
42:55 right about now the air is so hot it melts the solder in these Techntronics
agreed
im glad to see Mr Carlson take preemptive measures to combat the cold Canadian winter
by doing what? converting a possible 156KW of energy stored in the diesel being consumed, into approximately 27KW of heat in a resistor?
disele engine... 30% efficient... 52KW output, using approximately 156KW worth of diesel. generator, 50% efficient at full load, for 27KW of heat, the other half of the engines output being dissipated by the generator itself.
a heat exchange on the exhaust and cooling system would be far more effective use of the potential energy in the diesel, if ones primary goal was simply "workshop heating".
@@paradiselost9946I know right? Just build a bon fire in the shop and huddle around it for warmth like you would. Duh.
@@bullycabalrecruit2215why huddle?
not sure if you are being sarcastic or agreeing.
me? i would run a small diesel heater, use about 1/5th fuel, and release the same amount of heat. no huddling required. as the majority of heat in that fuel will be released and go towards heating air.
but i doubt the intention here was to simply produce heat. its a load bank. i assume its simply to test the generator. if its main primary purpose is to heat a workshop? then its an exercise in stupidity and ignorance.
@@paradiselost9946 These heaters are strictly used for dummy loads for testing the generator. THAT IS ALL! Did you watch the previous video where he specifically talked about using the heaters for dummy loads to test his generator to make sure it holds the load?
LOTS of high reliability generators are load tested for reliability. (Hospitals, 911 communications centers, data centers, food storage facilities and the list goes on and on). All of them are tested with dummy loads on a regular bases, to make sure they handle the load when needed!
How else would you load test a generator that is in high reliability service? The loads used are mounted on a large trailer. Some are the size of a semi trailer with huge fans, and lots of big cables hooked to the generator and transfer panel to test reliability.
We're talking about 250, 500 750 on up through multi megawatt capacity generators.
@@paradiselost9946 The comment is obviously a joke, why do you have to be a smartass when no one asked you to?
All my children's Easter eggs melted when you turned those heaters on.
I beg to differ with you Mr. C on the crimper. If you were to spin it 180 degrees, the crimper will force the seam together and put the dimple on the back side and will apply pressure of the crimp without the chance of missing the seam...which would be a failed crimp.
I've also had zero failures (in close to 5-decades) of using what you termed the double-oval type crimper. I do use a double-action crimper so a much greater force can be applied with less hand pressure (e.g. Sargent 3120)...they're good up to 10awg. for larger, I go to anvil type crimps and again, the dimple part goes on the BACK side of the crimp...the seam goes down into the smooth curved part of the crimper to force the seam together.
Yes, checking actual instructions will verify this. Also, store bought connectors all seen to be thin and weak (Chinese). They will not hold a crimped wire securely.
Correct use real connectors and i use a Knipex crimper always good connection
Although this is according to the instructions, what results is that the wire strands are pushed out through the split, as the sides pull back, opening the split because of the dimple. The only way to make them reliable and repeatable is to center the dimple on the split.
Look up what the manufacturers like Panduit want you to use. Those are the crimpers that do the job right and are certified. Everything else is a tradeoff. Even a well used brand name crimper (two dies in a ratchet) will do a better job than anything without a ratchet where you have no positive indication of a full crimp.
No, that is exactly wrong. Once you press in on the seam with the crimper, you create the opening that can allow strands to not be crimped. The seam is touching before the crimp is applied. If you have the seam down (away from the dimple, as you use the crimper, the seam is held together as the dimple presses in on the back, reducing the inside area for the wire, which allows for the crimp to work. There is no means for the wire to go through the seam as it never separates.
There are plenty of examples of crimping as Mr. Carlson showed where crimp quality is poor as many people will not precisely center the dimple. And, even if you do, you create the gap, which you don't want. There is no way that the method he showed is better than the "proper" way.
He can do it any way he wants, I just would never advise people to do it improperly (or against the manufacturer's instructions). As for regulatory approval, they almost always stipulate that a condition is to install as per the manufacturer.
Mind you, there are a LARGE variety of crimp manufacturers and quality of crimps as well as crimp tools so there are other variables at play here.
But hey...try it for yourself. Crimp with the dimple on the back (aways from the seam) and try another with it crimped so the dimple presses in on the seam. See if there is any improvement between one and the other. Then be just a smidge less precise when you are crimping and see how it goes and which way is more forgiving too.
There ARE crimp styles (typically smaller signal times) where part of the crimper's job is to have a proper die set that will curl over the crimp as well as also wrap the crimp around the insulation to form a straing relieve (e.g. a Dsub crimper)...but that is not the case for the types of crimps that he showed.
I didn't bring up the issue as a "gotcha" moment for Mr. Carlson either. I have the highest respect for him, his projects, his knowledge, his channel...etc. I was just surprised that he would go out of his way to recommend an improper method. Making crimps like the ones he was doing is something I've done countless times in the last half century. If it was just a technique thing, that would be something different. We all have our own styles. I, honestly, think what he recommended could lead to some people making very poor crimps.
I use the hell out of those cheap solid state relays in my garden to turn on lights, humidifiers, fans, etc, all esp32 controlled. They are amazing! Despite one or two DOA units, they are all very reliable in service.
Your comment about the LED bulbs got my attention. I have several different brands of bulbs at home and one brand is really sensitive to power line fluctuations. All of the bulbs of that one brand will blink at 2 Hz at different times of the day depending on how the grid is being loaded at the moment. The line voltage drops from around 122 to 117. It gets very noticeable around 4 PM EDT and also around 8AM when everybody has their coffee makers on! I never noticed this with the old incandescent bulbs. Thanks for the superb video.
I have noticed the same here, certain times of the day, the LED lights above the bench will flicker at about 2Hz. Thats interesting!
I worked for the power company for 32 years. One of my jobs was voltage regulation by switching in various sizes of capacitors. I notice cheaper LED lights are susceptible to the voltage changes on the grid. The smaller caps were around 20MX and the largest was around 300MX at 230,000 volts. MX stands for Mega VARS. They would go into service in the morning when everyone wakes up. Voltage goes up. Then after dinner time, most would come out of service. Voltage goes down. Great video.
Nice work! I'm building a load out of 500W and 1kW quarts lamps for my Onan generator.
If you want a frequency display that you can see from across the room, get a Korg DT-1 Pro guitar tuner. Replace the stock crystal with a programmable oscillator set to 6.177180MHz. That makes the A# setting exactly 60Hz. It'll show 58.28Hz to 61.76Hz. Each LED shows a 0.0375Hz change.
Double check that osc freq. I'm going off of my notes that are a few years old.
it is very satisfying when all the hard work you've done works, well done!!! as a retired union electrician, whether it is 22 AWG or 4 AWG or 00 we strip wire. the only bit I would like to add is that if wire is a single conductor, it is wire and not cable, and it matters not if its stranded. mike
A built in voltage and frequency meter is a must.
Frequency is a very important factor for motors.
@@timguishard4641 And televisions....
Beautiful implemented!!! 👍👏
I would have also like to see the waveform on a oscilloscope and the THD at different load levels.
I work on 10KW heaters for 1800 pound solder pots, we use the same ssr's to control strip heaters strapped around the solder pot to melt solder for electronics wave soldering. once while testing a system for a fault an assistant measured across an ssr and it exploded with the force and sound of a gun shot. a large piece of the top came off as an inverted cone and shot across the room narrowly missing the assistants head even the safety glasses may not have prevented injury had it hit. The input circuitry to this ssr was faulty and the probing allowed the ssr transistor output to bias at the half way max power point and the semiconductor superheated. In order to test for the fault the Polycarbonate shield covering the ssr banks was removed. I strongly suggest a Polycarbonate protective shield strip covering the body of all the ssr's. long pcb style standoffs are used to suspend the shield above the ssr's.
playing with simple ZVS induction heaters, i find i can make FETs explode instantly by pushing an iron bar into the coil when its running.
no issue if it STARTS with the bar in place, but to push it in when its already running? everytime, one FET simply explodes.
something about altered inductance, the decreased reflected impedance with appropriate increase of current draw, and the abrupt change in frequency that they dont appreciate...
I made a generator load from three 9kW new old stock shower water heater modules off eBay at £12 each, some hose, hefty cable and three 32 Amp MCB switches in a domestic consumer unit box, so like your good self, each 9kW module can be brought in and out. A hose to the outside tap flows unrestricted mains water through them, the waste going to a drain or just onto the ground.
Works well for testing generators and loading them for an hour or so to clear wet stacking.
I enjoy your channel, happy Easter and good luck.
Thanks for sharing your story Chris!
Mr Carlsons lab i wish you and your wife and kids a happy Easter 🐣 my friend
You have got the best lab I've ever seen, or dreamed about!
As a industrial power generation tech It would be cool to see you make some content about voltage regulation and speed control repairs. Lots of obsolete parts out there and more to come the way things are going. I would especially love to see you show how different loads create harmonics. I just had a site that has 95% of the loads consisting of VFDs. Customer was blaming the generator . Right now I have a temporary filter on it . Its amazing to see what it does to the sinewave. Love your content!
Thanks for your input!
More like 30Kw!! What a great shop genset! It’s using every bit of that 23hp Kubota diesel.
It's rating is 69.5 HP at 1800 RPM.
@@MrCarlsonsLab Wow! That’s even more impressive of a rig. Especially for a home shop. If it’s worth doing, it’s worth doing right!
Diesels work best when under a load. Solves the issue of using a big generator to power a house.😂
@@MrCarlsonsLab Even under full load, that engine sounds like it's barely working. Running at 1800 rpms is WAY better than 3600 rpms.
@@Mark.R_ wasting 27kW is a shame anyway. At this point accumulator setup would be preferable even economy-wise.
Thanks for setting the record straight, regarding where to put the dimple of the crimper. Having done many hundreds of these, including trying the other way (according to the 'instructions'), your way is far more repeatable and reliable.
You are very welcome!
I used my Ultra Probe to listen to an Evap canister solenoid to make sure it was actuating. Happy Easter Mr. Carlson. Bless you and your loved ones.
I really like this build video. Its a nice side-step from the usual. I run into so many young engineers who have honestly never actually designed AND built anything with their two hands.
Paul, I can't tell you how much I really enjoy these kinds of projects, along with fixing the old radios. 🤩 All the best from Gene in Tennessee.
Thank You for your kind feedback Gene!
63 hz to 59 hz is very good regulation for a mechanical governor. Back in the day, we used a salt water tank with 3 copper pipes lowered by a wench. All kinds of fun. As the water heated, the load went up, so if you got distracted ..... Fire Marshall asked me what it was. I said you do not want to know.
It must have been Fire Marshall bill. He loves that kind of thing.
That was a great video on your load bank setup. And I'm glad to see the exhaust/muffler arrangement has been done properly.
Wow I really appreciate the details you went through on construction of the test device and the whole process. Most youtubers skip over the details and people like me who are OCD thrive on details. Thank you.
I'm impressed with the speed stability. I did not hear any speed change with the change in load. My 20kw standby generator gets pissed off when I turn on the microwave.
This deserves a hearty "Tim Taylor Grunt"
No more cold winters. Cool design and workmanship.
Drive ALL those TRIAC switches at once with a function generator and a scope on the diesel generator's output so we can see some dynamic regulation! That's where the rubber meets the road.
Now thats the way to test a generator. Loved it. I also saw a HP 608 on the lower shelf to the right? I just received 11 of those.
I always wanted to see this other side of the laboratory. The drilling area, the manufacturing of the boxes and everything else. Excellent video. Thank you always for sharing!
Mr. Carlson's Lab: The Next... Generation... ⚡🤓👍
I believe that the split the connector should go into the radius portion of the linesman pliers with the pointed portion acting on the non split side of the connector. I believe this is the preferred way from most manufacturers. That way the connector Barrel doesn't spread open and the wire is held nicely by the divot left by the pointed side of the crimping die. I am only speaking of using the split connector with the type of die on the linesman pliers. I love your content. You are one smart fellow!
With all the positive comments, I can add this. We see a man that's confident in his work that he did not need the safety grounds hooked up for this test.
Lets say, he is using a "floating ground"
I will say that if he generator is not grounded (isolated) nothing will flow to ground trough anything, only between phases and neutral ... 😛😝
So much to learn from this channel. Some of the best content on the web. Really appreciate all your work Paul. Surprisingly little deviation of the current as the elements warm up. Nice rig.
Hi Mr. Carlson,
Fun fact about that particular brand of solid state relays.
We purchased a batch of them to replace failing ones in T-shirt presses, however, they did not function correctly.
It turns out their minimum "pull in voltage" of 3v was actually more around 5-6v. The temperature controllers in the presses were outputting about 3.4v.
Therefore, the relays would never allow current to pass.
Your model of relays may not be the same as the ones we were using.
Figured I would let you know about our experience.
brilliant Paul.. thank you...
And all these years I thought you were just working out of a corner of your basement but damn what a shop
(edit) before you start hating on me im years behind.
All's good! :^)
My dream backup generator. We run our home on a 7kw portable. Last winter we lost power 3 weeks and the year before that it was almost 5 weeks without power. I have a manual transfer switch and current and voltage of the system that can be viewed inside to help keep a eye on whats being used.
Thank-you Mr. Carlson as always a great video with a technical master. Thank-you
Back in the early eighties as a young lad I worked in the sound and lighting industry. Monday mornings we had DJs coming in with destroyed lighting controllers and molten 6v 36w pinspot (PAR36) transformers. This is how I learnt all about non zero crossover switching applied to resistive verses inductive loads on 1970s 'chasers". Of course, all lighting controllers moved to zero switched as time progressed. I even remember the triac was a BTA08 400s with an isolated tab. :-)
Zero cross opto's are very nice. I use them even when not needed in AC switch design.
Fantastic project, i really love seeing more of these videos 🎉
Please consider storytelling while mounting stuff on. 🤗
Will do!
This was amazing to watch. I love the care you took in constructing an experiment. Thank you for showing this!!!
You're very welcome Harry!
Nicely done on the exhaust/muffler arrangement. 👍
That generator wasn't even breaking a sweat. Good voltage regulation! I'd like to see how its frequency varies over time and with load. It would be interesting to see just how good the governor is.
Great work ! Happy Easter to you and your family and friends Mr. Carlson.
Very well done.
Mr. Carlson is a genius.
Looks like a total success. The voltage regulation seemed very good and minimal voltage drops on inrush currents.
A very pleasant cathartic build video, thanks 🙂
Amazing project 👌
Awesome as Always,,, Really interesting vid thankyou
Glad you enjoyed it!
Mr. Carlson is awesome! What a cool video. I love relays.
Another fun day with Mr. Carlson.
Mr Carlsons lab you are good at restoring antique radios and alignment of antique radios 📻 my friend
@MrCarlsonsLab Did you build this load bank in order to do monthly tests of your backup generator?? I'm a Data Center Design Engineer and have been designing and building backup power systems for Data Centers for the past 35 years in the 10 to 50 megawatt size. If you're going to use this load bank to do monthly tests I would recommend you make the cables long enough to put the load banks outside and run the generator for a minimum of one-half hour at 90% load. Any less and cylinders will not heat up to full stretch and you'll create a ridge on the top of the cylinder and also wet stack the generator.
Great project. Learned a lot.
Mrister Carlsons lab this awesome 27000 watt load complete build my friend
Great video and explanations, I like how you put things together, considering every little detail,even how to use a crimper. You have a beast of a generator there. 👍👍👍👍👍
Back in 1996 I used to build generators for a company called Stephill Generators and we had a near identical test setup with 500 watt halogen bulbs (the type used in garden security lamps). 500w, 1kw, 2kw and 4kw switched in. Basically we could test generators from 1.2kva right up to 8.5kva (some 10kva too but only 7500w). As the bulb box was a meter cubed we really did net feel the heat but instead got blinded by the light escaping through the Louvres. The bulbs worked great as a purely inductive load and aided setting the frequency 50hz in the UK, and the voltage. The engines we used for also welder generators (portable arc welders) were Honda GX390 for the largest with Lister petter, Rugerrini, Lombardi, Briggs and Stratton and Yanmar diesel but by far the most reliable engines were Honda for petrol and Lister Petter for diesel. Great video Paul and the other beach used to build huge generators somewhat larger than this. The last I worked on was a Rolls Royce 250kva and PetBow alternator. I can’t tell you home much this engine handled 250kva without breaking sweat. Mecalte and Markon alternators simply couldn’t compete!!!
That four core extension might be the first time I'd ever feel justified in owning one of those bead-style cable strippers.
Thank you Mr Carlson. You are the finest on youtube! Because of you i challenge myself even harder to get results that are so satisfying.
Thank You for your kind feedback Carol!
Impressive kit. I'm not sure what I'm more impressed with.. the amount of effort you put into building that test rig or how quickly that genset responds to load changes. Looked like around 4% momentary dip when doubling the load from 60->120amp and very little overshoot either when cutting it out.
Love your work and presentation.
Happy Easter my Freind...
Paul a great detailed video you do such wonders and have amazing talents I learn a lot from you and enjoy every moment. Well done video thanks
Thanks for your kind comment!
Excellent experiment result. Wishing you and your family a happy Easter.
Great knowledge Mr Carlson sir you are awesome engineer thanks thanks for sharing this video sir ❤❤😊😊
Amazing, thats a great project.
Just subscribed. I've been watching and enjoying your restoration videos for some time. Finally, I caught this one newly shared. It's the only one I've seen that shows the larger view of your work area. Wow 😮 what a space ! I'm totally envious ! I can imagine the struggle to adequately heat that area and like your solution. Here in GA 🇺🇸 it's the opposite problem. I roast most of the year in high humidity 🥵. High praise for the care and effort you put into all of the vintage equipment you restore. Your attention to detail and preserving the original design of old tech is top tier 🏆! Not many respect original design the way you do. Your love of vintage electronics rings through loud and clear. I'm also envious of your collection ! Again, just...Wow 😮
Welcome aboard!
Awesome project.
watching you build things relaxes my mind
Thank you.
You're welcome!
This was beyond cool to watch, thank you Professor Carlson for this entertaining project video !!
My pleasure!
Mr Carlsons lab your CZcams videos 📹 are awesome my friend
Nice job and a great piece of equipment.
I spent half the video admiring how clean and organized your shop was. :P
Fantastic sir
So all the filming happens in this place , at least the beginning of his exciting videos do, the "Let's get started" bit. As I saw all the test equipment and radios on shelving...
*Fantastic* Mr Carlson.
Thanks Mr C for another great video, this was way more work than it seemed on film I'm sure. The wire looming alone shows meticulous thought and dedication especially as this was a mock up of the final product. Would like to see the final result when completed. Definitely a nice set up and power to spare. Crimper Wars👈 Thanks again and Happy Easter.
I would love to see you explaine how to wire a big generator 3 phase that is and explanation of why you can only use 2/3 of the power of one when in double delta or zig zag and if it’s better to use a Y configuration
This is Zig-Zag.
Excellent work Mr. Carl, as usual.
HOLY MOLY, now i know why scopes are so expensive. There is one man hoarding all of them in his workshop!
If you wanted to build a dummy load for an electric chair, about 15kW would be enough. As far as I know applied voltage is 1'500VAC while an internal body average body resistance of 150 Ohms is assumed. This results in a current of 10 Amps and 15kW frying power. to test the chair before usage, a dummy load is connected (Source: Dept. of correction, Florida).
That’s one beefy generator to only lose a couple volts with a 120 amp load on it. Good call on that main power cable, very pricey stuff but the fine strand wire makes for a much easier cord to manipulate than the stiff heavy gauge stuff with a solid wire ground. Thank you for sharing and have a happy Easter.
Very nice generator unit. It loaded and recovered *very* quickly. Minimal voltage/frequency drop. Lots of headroom. I used an old Lister air cooled 25hp 3 phase diesel generator for my machine shop for quite a while. It was a nice reliable unit but had terrible recover. Changed it out for an old Ford 4 cylinder 60hp marine diesel which was much better before finally getting a 3 phase hydro service.
As soon as I can get my hands on a vision aid that will allow me to work on electronics hands-on, I'll be subscribing to your Patreon. I've been reading up on electronics since I was 16 (that was a long time ago lol) and have watched 1000's of CZcams videos, and am dying to practice the art.
Welcome aboard!
Thank you again for another great video!
You videos are both entertaining and educational!
My pleasure!
Big Clive tore down the Fotek SSRs. He found that they are definetly under-engineered and over-rated. IIRC, I am using a Crydom 1225 SSR to switch the heating elements on my DIY Reflow Oven. IIRC, that SSR only requires 7mA to trigger it. So, I am driving it directly from a PIC MCU (could be any MCU) straight off of a pin. It has worked well for years. Adding an optocoupler between the MCU pin and the SSR would have been a nice safety feature, but I did not know about those at the time I built the oven. Of course, using a MCU affords also sorts of additional control and data collection, such as PID PWM and reflow temperature profiles. And, yes, additional heat sinks (more than just the mounting plate) are needed. HTH. Cheers.
That's one serious generator!
Neat! I've used one of those Fotek SSR's for a spot welder I made with a rewound MOT :)
That was a treat. I loved the construction footage and testing. One can only wonder what types of jobs and experience you had growing up. I don't believe I've seen anyone with so many talents..
That generator is a BEAST !!!
Build a couple fold out, or roll out "walls" lined with rock wool insulation facing the generator. Not even remotely close enough to keep the heat in, but to absorb and block a lot of the noise. Neat load bank, thanks for sharing!
Always a great pleasure watching your videos sir. Congratulations from Aotearoa New Zealand 🇳🇿
Very nice!
some of your best content so far, excellent
The Florida pool pump motor repair guy 32750 approved ! that was good info & see Mr Carlson
More power Egor! Yes Master. See to the Lyden Jar. Yes Master.