Gen on Generators

Spray Foam Magazine – Spring 2022 – Investing in the right power for your rig can save money in the long run. For example, sizing the generator properly for durability will ensure less electrical component failures. The Spray Foam Magazine team asked a few experts on their top tips for considering generators.

WINCO GENERATORS mascot, “Big Dog”, was kind enough to answer the following questions.

Spray Foam Magazine: What do you consider when recommending the correct size generator for a rig?

Big Dog: It is critical to match your generator size to the load you have. An under-sized generator will give more variation in electrical performance, and it will fail quicker. If you oversize a diesel generator it will operate at colder temperatures than is healthy, leading to increased maintenance costs. Understanding what your load is going to be is the first step to choosing the right generator.

SFM: What is the most common troubleshooting question you receive?

BD: ‘Can I change the voltage on the generator?’ If the generator is a 12-wire generator end it can be changed to the voltage you need. If the end is a 6-wire it is dedicated and can't be changed.

SFM: Have you had any standout unique requests?

BD: We have received requests for more power on gasoline as well as lighter weight more durable products. So, right now, we are working on an 1800 rpm gasoline unit and a new combo unit that is smaller than the 4040 combo. We use this engine in other industries, so we brought it to this unit too.

SFM: What is your top generator maintenance tip?

BD: Remember to check with and hire a professional generator maintenance company to keep it in good working order and stay on top of your preventative maintenance.

SFM: What common errors do you see from those just starting out in the spray foam industry?

BD: Generators that are too small for their application are common. Make sure that your diesel generators are loaded as much as possible. Idling under low load for long periods of time will reduce the life of the engine.

Gino Kennedy, president of Next Generation Industrial Power Solutions, shares his expert opinion on all things generators.

Spray Foam Magazine: What do you consider when recommending the correct size generator for a rig?

Gino Kennedy: When recommending a generator size, the main considerations are: 1) is it a one or two proportioner rig and 2) what is the size and amp-draw of the heater in the proportioner? It is also beneficial to know other electric loads that could be used in the rig, and a big question is whether or not an electrical compressor will be run.

Up until the last 10 years, typically, spray rigs would run an oversized 3-phase generator to help deal with the massive startup load of a large electrically driven air compressor. Obviously, this is extremely inefficient using horse power to make electricity to convert back to horsepower to drive a compressor. This is also why most rigs were built with 3-phase gen-sets to easier start electric compressors.

Alternatively, several companies, including ourselves, build generator-compressor combinations. These are engine driven gen-sets with mechanically driven compressors. Most are belt driven while the Next-Gen is a direct coupled rotary vane unit. Either way, a mechanically driven compressor is far more efficient than an electric motor driven machine, and there is no inrush current to disrupt the electrical output of the generator. Another benefit of the combination units is there is no real need to wire rigs 3-phase, as the only 3-phase component was the air compressor.

SFM: What is the most common troubleshooting question you receive?

GK: I would say on a new installation, fuel supply problems are common. If a fuel tank is too far away or any clamps are loose, air intrusion on a diesel set will cause intermittent or complete shut down.

SFM: Have you had any standout unique requests?

GK: Unique requests usually pertain to different combinations of electric to air output on our combination sets.

SFM: What is your top generator maintenance tip?

GK: Other than the standard change in oil, fuel and air filters, cleaning out the air intakes on the generator and compressor cooling systems is critical. Most rigs have a lot of foam debris floating around.

SFM: What common errors do you see from those just starting out in the spray foam industry?

GK: From a gen-set manufacturer standpoint, we see many startups using underpowered gas generators that are not designed to start electric compressors. This causes voltage and sign wave fluctuations, causing trouble with proportioner controls. Also, gas generators should not be run inside trailers as they emit carbon monoxide that can kill you.