Rajan Wilcox
Connecting an external fuel tank to a generator can be a convenient way to extend the runtime of your generator and avoid frequent refuelling. This setup is particularly useful in situations where you need reliable power for extended periods, such as during power outages or when living off-the-grid. The process involves either connecting the external tank directly to the generator's fuel line or utilising a fuel transfer pump and supply line. It is important to consider the potential risks, such as fuel spillage or leakage, and take appropriate precautions. Additionally, maintaining the fuel quality and controlling the temperature are crucial to ensure the generator functions optimally.
Characteristics and Values for Connecting an External Fuel Tank to a Generator
| Characteristics | Values |
|---|---|
| Hose length | No less than 15 feet long, with an inside diameter of 5/16” or 3/8”. If the hose exceeds 15 feet, step down the hose size to ¼”. |
| Hose type | Black iron pipelines with no welding. Avoid galvanized steel, copper, cast iron and aluminium pipelines. |
| Hose connection | Use zip ties or hose clamps to keep the hose in place. |
| Fuel tank placement | The fuel tank should be placed near the generator, but not directly on top of it. |
| Fuel transfer | Use a fuel transfer pump to transfer fuel from the external tank to the generator. |
| Fuel supply line | Install a supply line and a return line, with a minimum clearance of 50 cm between the two lines to prevent fuel heating and impurities. |
| Fuel storage | Use clean tanks for fuel storage and periodically empty the tank to drain water and sediment. |
| Fuel overflow | Install a non-return valve at the genset's fuel inlet to prevent fuel overflow in case of a level difference between the genset and external tank. |
| Fuel spillage | Ensure the storage tank supply line is installed at least 5 cm from the bottom of the tank to prevent spillage due to fuel expansion when hot. |
| Fuel connection | Use a fuel tank cap with a hose barb or quick connect feature to connect to the internal tank of the generator. |
| Fuel types | Diesel fuel is recommended over gasoline due to lower volatility and safety concerns. |
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What You'll Learn
Quick-connect fuel tanks
Understanding Quick-Connect Fuel Tanks:
Selecting the Right Components:
When setting up a quick-connect fuel tank system, it's important to choose the appropriate components for your generator. Ensure that the fuel tank, hose, and connectors are compatible with your generator model. You can opt for purpose-built solutions specifically designed for your generator brand, or you can explore more versatile options. Additionally, consider the length and diameter of the hose, ensuring it meets your safety and convenience needs without causing fuel starvation issues.
Installation Process:
To install a quick-connect fuel tank, begin by setting up a quick connect on your generator. This can be achieved by utilising a special fuel tank cap that connects to the internal tank of the generator. Fully drain and disconnect the internal tank, and then connect the remote tank's hose directly to the intake hose leading to the carburetor. You can choose between "hose barb" and "quick connect" fittings, depending on your preference for permanence or ease of connection. Ensure that the hose is securely attached using hose clamps or zip ties.
Additional Considerations:
When working with quick-connect fuel tanks, there are a few important factors to keep in mind. Firstly, ensure that the external fuel tank is placed at an appropriate height relative to the generator. This will impact the flow of fuel and the effectiveness of the system. Additionally, consider installing a non-return valve at the fuel inlet to prevent fuel overflow in case of level differences between the generator and the external tank. It is also crucial to maintain the fuel tank by periodically emptying it to remove any water or sediment buildup, controlling the fuel temperature, and avoiding long storage periods.
Alternative Methods:
If you prefer an alternative approach, there are other ways to connect an external fuel tank to your generator. One method involves setting up a pulse pump to run the second tank, utilising a standard gas can with a drilled hole for the fuel line. Another option is to use a 3-way valve, similar to those found on zero-turn mowers with two tanks. This allows you to switch between the generator tank and the external tank, providing flexibility in fuel sources.
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Using a pulse pump
Connecting an external fuel tank to a generator can be a complex process, and it is important to consider safety at all times. It is recommended to consult a professional for advice and guidance.
The pulse pump can be connected to the external fuel tank by drilling a hole and installing a fitting. This will allow the pulse pump to draw fuel from the tank. The pump should be mounted higher than the fuel tank to ensure proper fuel flow. The pump can then be connected to the generator's fuel line, either directly or through a ""T" fitting if the generator has an existing fuel tank.
When using a pulse pump, it is important to maintain the fuel level in the generator's tank to avoid air locks and ensure proper fuel flow. This may involve periodically refilling the generator's tank or using a selector valve to switch between the external and internal tanks.
It is also crucial to consider the placement of the external fuel tank. The supply and return lines should be installed as far apart as possible, with a minimum distance of 50 cm between them. The fuel lines should be as close to the bottom of the tank as possible, with a minimum distance of 5 cm, to prevent air from entering the system. The fuel storage tank should be located as close to the engine as possible, preferably within 20 meters, and both should be on the same level.
Additionally, it is recommended to install a non-return valve at the generator's fuel inlet to prevent fuel from overflowing if there is a difference in level between the generator and the external tank.
By following these steps and considerations, you can successfully connect an external fuel tank to a generator using a pulse pump, ensuring proper fuel flow and maintaining the safety of the system.
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Gravity-fed systems
Connecting an external fuel tank to a generator is a great way to ensure you have an extended run time and a fresh fuel supply. This is especially useful in situations where you need to generate power for long periods, such as during a hurricane or power outage.
- Place the external fuel tank: The external fuel tank should be placed at a higher elevation than the generator. This can be achieved by using a stand or placing the tank on a platform. Ensure that the tank is secure and stable to avoid any accidents.
- Connect the fuel lines: You will need to purchase a fuel transfer pump and fuel supply line. Connect the supply line from the external tank to the generator's fuel intake hose or carburetor. Use quick connectors for a simple and fast connection.
- Ensure proper fuel flow: To ensure smooth fuel flow, you may need to drill a hole for the fuel line in the external tank and open the vent or create a vent in the cap. This will allow air to enter the tank and facilitate fuel flow.
- Maintain fuel level: Keep an eye on the fuel level in the external tank. As the fuel level drops, air may enter the system, disrupting the fuel flow. To prevent this, ensure that the supply line is installed deep enough in the tank, leaving a distance of at least 5 cm from the bottom.
- Prevent fuel overflow: If there is a significant difference in elevation between the generator and the external tank, consider installing a non-return valve at the generator's fuel inlet. This will prevent fuel from overflowing when the generator is turned off or during periods of low fuel consumption.
- Safety considerations: Always use clean tanks for fuel storage and periodically empty and clean the tank to remove any water or sediment build-up. Avoid long storage periods, and control the temperature of the fuel to maintain its quality.
By following these steps, you can successfully set up a gravity-fed system to connect an external fuel tank to your generator, ensuring a continuous fuel supply and extended run time for your generator.
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Fuel transfer pumps
First, it is important to ensure that the fuel tank and generator are compatible. The fuel tank should be clean and in good condition, and the generator should be fitted with the appropriate connections and valves. It is also crucial to consider the clearance between the supply line and the return line, as per the recommendations of the pump manufacturer. The distance between the two lines should be maximised to prevent the fuel from heating up and to avoid any impurities that could harm the engine.
Next, the fuel transfer pump should be installed according to the manufacturer's instructions. This may involve connecting the pump to the generator's fuel intake hose or carburetor, or it may require the use of a 3-way valve if the generator has an internal tank. The fuel supply line from the external tank should be connected to the generator's connection point, ensuring that the line is installed as deep as possible and at least 5 cm from the bottom of the tank to prevent air from entering the system.
Additionally, it is recommended to install a non-return valve at the generator's fuel inlet to prevent fuel overflow in case of a level difference between the generator and the external tank. When filling the external tank, it is important to leave a free space of at least 5% to accommodate fuel expansion and prevent spillage.
The length of the hose connecting the external tank to the generator should also be considered. While hoses can be purchased in various lengths for safety and convenience, longer hoses may affect fuel delivery. If the hose is over 15 feet long, it is recommended to reduce the hose size to 1/4" to ensure adequate fuel supply.
Finally, it is important to periodically inspect and maintain the fuel transfer pump and external tank system. This includes emptying the tank to remove any water or sediment, controlling fuel temperature, and replacing the fuel within its lifespan to ensure optimal performance.
By following these steps, a fuel transfer pump can be successfully utilised to connect an external fuel tank to a generator, ensuring a reliable and efficient fuel supply for the generator's operation.
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Hose and connector types
When connecting an external fuel tank to a generator, there are a few different hose and connector types that can be used. The specific type you will need depends on the make and model of your generator, as well as the type of fuel tank you are using. Here are some of the most common options:
Hose Barb
The hose barb connector is a more permanent solution for connecting an external fuel tank to a generator. It typically involves a hose that is secured to the generator's fuel intake with a hose clamp or a zip tie. This type of connection is designed to be more durable and long-lasting, but it may be more difficult to disconnect and reconnect compared to other options.
Quick Connect
The quick connect system offers a faster and more convenient way to connect an external fuel tank. It usually involves a special fuel tank cap that connects to the generator's internal tank. This type of connection is designed for ease of use and can be quickly connected and disconnected without the need for additional tools or equipment.
Fuel Transfer Pump
If you are connecting an external fuel storage tank to a generator, you may need to install a fuel transfer pump. This setup typically involves connecting the fuel supply line from the storage tank to the generator's connection point. It is important to ensure that the fuel lines are properly secured and maintained to prevent leaks and spills.
Pulse Pump
In some cases, a pulse pump can be used to draw fuel from an external tank. This method typically involves drilling a hole in the fuel tank and installing a fuel line that connects to the generator's fuel intake. A pulse pump can be a simple and cost-effective solution, but it is important to ensure that the fuel line is properly secured and primed before use.
Fuel T-Valve
For generators with a fuel pump, a fuel T-valve can be installed to facilitate the use of an external fuel tank. This setup involves connecting the T-valve to the generator's fuel line and the external fuel tank. It allows for a more flexible fuel supply system and can be a useful option for generators with complex fuel delivery mechanisms.
When selecting the appropriate hose and connector type for your external fuel tank, it is important to consider factors such as compatibility, ease of use, and safety. Consulting a professional or a generator specialist can help ensure that you choose the right components and that they are properly installed.
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Frequently asked questions
There are several ways to connect an external fuel tank to a generator. One way is to disconnect the fuel line from the carburetor and attach the line from the external tank to the carburetor. Another way is to use a fuel transfer pump and connect the fuel supply line from the storage tank to the generator's connection point.
The quickest way to connect an external fuel tank to a generator is to disconnect the fuel line from the carburetor and attach the line from the external tank to the carburetor.
It is important to take safety precautions when connecting an external fuel tank to a generator to avoid fuel spillage or leakage. One way to do this is to install a non-return valve at the generator's fuel inlet to prevent fuel from overflowing. Additionally, the storage tank supply line should be installed at least 5 cm from the bottom of the tank to prevent air from getting in when the fuel level drops.
Here are some tips for connecting an external fuel tank to a generator:
- The distance between the fuel lines and the bottom of the tank should be as short as possible, ideally no less than 5 cm.
- The connection between the hose coming off the external tank and the hose leading from the built-in tank to the carburetor is important. Consider buying something purpose-built for your brand of generator that facilitates the flow of gas from an external tank.
- When filling the tank, maintain a free space of at least 5% to prevent possible spillage due to fuel expansion when it gets hot.
- Avoid using galvanized steel, copper, cast iron, and aluminum pipelines as they can cause problems for fuel storage and/or supply.
