Regan Brown
An external fuel tank for a generator is a great way to increase its running time and ensure that the internal tank stays at the required level. This is especially useful in situations where refuelling is not possible or inconvenient, such as during a hurricane or power outage. To build an external fuel tank, you will need to consider the location, materials, dimensions, and components of the tank, ensuring compliance with regulations. The tank can be connected to the generator using a fuel transfer pump and supply line, or by using quick connectors and hoses. It is important to take into account the potential hazards of fuel spillage or leakage and to maintain a clearance between the supply and return lines to prevent fuel from heating up and causing impurities.
Characteristics and Values Table for External Fuel Tanks for Generators
| Characteristics | Values |
|---|---|
| Purpose | To increase the running time of the generator, satisfy special demands, and address issues with limited fuel reservoirs and frequent refuelling. |
| Installation | Install an external fuel storage tank, a fuel transfer pump, and connect the fuel supply line to the generator's connection point. Ensure compliance with regulations for oil installations. |
| Distance and Level | Place the external tank within 20 meters of the engine and at the same level to prevent fuel heating and impurities. |
| Connection Type | Use quick connectors, hose barbs, or a combination of both depending on the generator model and specific requirements. |
| Hose Considerations | Ensure appropriate hose length and diameter to avoid fuel starvation. Step down the hose size for longer hoses to maintain adequate fuel flow. |
| Fuel Transfer | Utilize gravity feed, fuel pumps, or vacuum methods to transfer fuel from the external tank to the generator. |
| Safety | Prevent fuel spills and explosions by carefully considering the fuel supply lines, connections, and characteristics of the generator model. |
| Storage and Direct Feed | Use the external tank for storage or feed the generator directly from the tank based on specific needs. |
| Non-Return Valve | Install a non-return valve at the fuel inlet to prevent fuel overflow due to level differences between the generator and external tank. |
| Ventilation | Properly ventilate the external tank to manage pressure and vacuum conditions during fuel consumption. |
| Fuel Type | Consider the fuel type (gasoline, propane, etc.) and ensure compatibility with the generator and external tank setup. |
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What You'll Learn
Using a boat gas tank as a fuel source
There are a few ways to go about using a boat gas tank as a fuel source for a generator. One way is to use a "quick connect" setup, which involves adding a short length of hose to the flange that points to the boat tank connection and then using a "quick connect" fitting to mate with the female fitting on the tank. It is important to ensure that the hose fits tightly to prevent dangerous leaks. The length of the hose can vary, but if it is over 15 feet long, it may be necessary to step down the hose size to ensure adequate fuel flow.
Another method is to use a gravity feed system, which involves placing the boat tank higher than the generator and using a rubber marine fuel line to siphon the gas into the generator's metal input tube. This method may not work as well if the generator's fuel line is full of liquid, as the fuel will only be pulled upward from the secondary tank to the amount the primary tank goes down.
Additionally, it is possible to connect the boat tank directly to the generator's internal tank by using a special fuel tank cap and a hose barb or quick connect fitting. This method may require draining and disconnecting the internal tank first.
When using a boat gas tank as a fuel source for a generator, it is important to consider the potential for fuel spillage and leakage, and to ensure that the setup complies with any relevant regulations. It is also recommended to keep the fuel storage tank close to the engine and to use a supply line and a return line to prevent the fuel from heating up and causing issues with the engine.
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Quick-connect setup
Setting up a quick-connect external fuel tank for your generator is a great way to improve its running time and reduce the hassle of frequent refuelling. Here's a step-by-step guide to help you set up a quick-connect system:
Step 1: Choose the Right Tank and Location
Select an appropriate external fuel tank that suits your generator's fuel requirements. It is recommended to place the external tank as close as possible to the engine, ideally within a 20-metre maximum distance, and ensure they are on the same level.
Step 2: Prepare the Generator
Before connecting the external tank, ensure your generator is properly set up. This includes filling the generator's internal tank and preparing the fuel line. If your generator has a fuel pump, you may need to prime the line first.
Step 3: Connect the Hose to the External Tank
Attach a hose to your external fuel tank. The hose should be long enough to reach the generator comfortably. Ensure the hose is securely connected to the tank to prevent leaks. You may need to drill a hole in the external tank and use a hose clamp or zip tie to secure the connection.
Step 4: Connect the Hose to the Generator
Connect the other end of the hose to your generator's fuel intake. This may involve using a modified gas cap or a quick-connect fitting. Ensure that all connections are secure and tight to prevent fuel leaks.
Step 5: Test the Setup
Once the connections are made, start your generator and observe if it draws fuel from the external tank. Depending on the generator's design, you may need to ensure the internal tank is partially emptied before it starts drawing fuel from the external source.
Additional Considerations:
- Ensure that the hose diameter is appropriate for the length of the hose to avoid fuel starvation issues.
- Consider installing a non-return valve at the generator's fuel inlet to prevent fuel overflow in case of a level difference between the external tank and the generator.
- Keep the fuel lines clear and maintain a clearance between the supply and return lines to prevent fuel heating and to avoid impurities.
- Always follow safety precautions when working with fuel systems, and ensure your setup complies with relevant regulations.
By following these steps, you can quickly and effectively set up an external fuel tank for your generator, improving its runtime and convenience.
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Hose length and diameter
When making an external fuel tank for a generator, the hose length and diameter are important factors to consider. The hose connects the external fuel tank to the generator's internal tank or carburetor, ensuring a consistent fuel supply. Here are some key considerations and guidelines for determining the appropriate hose length and diameter:
Hose Length:
- The distance between the external fuel tank and the generator: It is recommended to place the external fuel tank as close as possible to the generator engine. The maximum distance suggested is 20 meters. However, keeping the tank closer reduces potential issues with fuel flow and pressure.
- Elevation considerations: If the external tank is elevated above the generator, it can aid in fuel flow due to gravity. However, ensure that the elevation difference does not exceed the fuel pickup level, as it may cause fuel starvation.
- Hose management: Consider using zip ties or similar fasteners to secure the hose to the generator frame or a nearby structure. This ensures that the hose is safely managed and doesn't pose any tripping hazards or restrictions to generator mobility.
Hose Diameter:
- Fuel flow and pressure: A narrower hose diameter may be necessary for longer hoses to maintain adequate fuel pressure and flow rate. For example, if the hose exceeds 15 feet in length with a 5/16" or 3/8" inside diameter, stepping down to a 1/4" diameter can improve fuel delivery.
- Compatibility with connections: Ensure that the hose diameter matches the connections on the external tank, the generator's internal tank, and any intermediate components, such as fittings or adapters. Incompatible diameters can lead to fuel leaks or inefficient flow.
- Fuel type and viscosity: Different fuels have varying viscosities, which can affect the optimal hose diameter. Thicker or more viscous fuels may require a larger diameter to ensure smooth flow, while thinner fuels can work with narrower diameters.
It is important to note that the specific requirements for hose length and diameter may vary depending on the generator model, fuel type, and other factors. Always refer to the generator's manual or seek advice from a qualified technician before finalizing the hose configuration. Additionally, follow safety guidelines and regulations to prevent fuel leaks, spills, or other hazards associated with external fuel tank setups.
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Fuel transfer pump
To make an external fuel tank for a generator, you will need to install a fuel transfer pump and a fuel supply line from the storage tank to the generator's connection point. The fuel transfer pump ensures that the generator's internal tank stays at the required level. This can be done by connecting the external tank directly to the generator's intake hose or carburetor.
There are a few options for the fuel transfer pump and fuel supply line. One option is to use a manual or electric fuel transfer pump, which can be purchased from various retailers such as Amazon. The pump should be placed in an appropriate location, considering the distance and level difference between the generator and the fuel storage tank. The fuel supply line should be installed as deep as possible in the storage tank, leaving a distance of at least 5 cm from the bottom to prevent air from getting in when the fuel level drops.
Another option is to use a gravity-fed system, where the fuel is pulled upward from the secondary tank as the primary tank is depleted. To ensure this works effectively, the fuel line must be full of liquid, and the vent must be at the top of the primary tank with a tube extending to the top of the secondary tank.
It is important to maintain a clearance between the supply line and the return line inside the tank to prevent the fuel from heating up and to stop any impurities from entering, which could be harmful to the engine. Additionally, the fuel storage tank should be located as close as possible to the engine, preferably within 20 meters, and both should be on the same level.
It is also recommended to periodically empty and clean the fuel storage tank to remove any decanted water or sediment, and to control the temperature of the fuel as excessive increases can reduce its density and lubricity.
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Installation and safety considerations
Installation Considerations:
- Location: The fuel storage tank should be placed as close as possible to the engine, ideally within a maximum distance of 20 metres. Both the tank and the engine should be on the same level to ensure proper fuel flow.
- Fuel Transfer Pump: To maintain the fuel level in the internal tank, install a fuel transfer pump in the generator set. This will help facilitate the transfer of fuel from the external storage tank to the generator's internal tank.
- Supply and Return Lines: Install both a supply line and a return line for the external fuel tank. This setup allows the engine to draw fuel from either the external or internal tank using a 3-way valve. Ensure a clearance between the supply and return lines to prevent fuel heating and to avoid impurities from entering the engine.
- Quick Connectors: Utilise quick connectors to establish a secure and efficient connection between the external installation and the generator set. This simplifies the process of swapping out fuel tanks.
- Hose Length and Diameter: Consider the length and diameter of the hose connecting the external tank to the generator. Longer hoses may require a smaller diameter to maintain adequate fuel flow and prevent the fuel pump from working overtime.
- Non-Return Valve: 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 the external tank.
- Fuel Pickup Hose: Ensure the external fuel tank has a pickup hose that reaches from the bottom of the tank to the top, where it connects to the fuel line leading to the generator. This ensures that fuel can be drawn out effectively.
Safety Considerations:
- Compliance with Regulations: Adhere to the regulations governing oil installations for own use. Ensure that the installation, ventilation, and inspection of the external fuel tank comply with applicable standards and guidelines.
- Fuel Spillage and Leakage: Take extra care during installation to avoid potential hazards due to fuel spillage or leakage. Even a small spark near a fuel spill can lead to a fire or explosion.
- Ventilation: Proper ventilation is crucial to prevent the build-up of flammable vapours and to mitigate the risk of explosion. Ensure the external fuel tank is adequately vented.
- Overpressure: Monitor the external fuel tank for any signs of overpressure. While it is expected that a vacuum will form as fuel is consumed, certain conditions, such as engine heat, can lead to overpressure.
- Fuel Freshness: Stale fuel can cause operational issues. Consider using a sealing fuel cap that meets EPA/CARB requirements to help keep the fuel fresh and prevent the escape of volatile compounds.
- Fuel Compatibility: Ensure that the external fuel tank is compatible with the generator's fuel type. Using the wrong type of fuel can cause damage to the generator and pose safety risks.
- Regular Maintenance: Establish a maintenance routine that includes checking fuel levels, inspecting hoses and connections for leaks, and ensuring that all components are secure and functioning correctly.
By carefully following these installation and safety considerations, you can ensure the safe and effective use of an external fuel tank for your generator.
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Frequently asked questions
An external fuel tank can increase the running time of a generator and reduce the need for frequent refuelling. It can also be used to maintain the level of fuel in the internal tank.
It is important to comply with regulations governing fuel installations, such as location, materials, dimensions and components. The installation process must also be done correctly to avoid hazards due to fuel spillage or leakage.
The idea is to adapt remote fuel tanks to generators, allowing the use of alternative fuel sources such as boat gas tanks. This can be useful in situations where reliable power is unavailable, and it eliminates the need to wait for the generator to cool down before refuelling, reducing the risk of spilled gas and potential explosions.
Examples include the Attwood Portable Marine Boat Fuel Tank, which is EPA-certified and has a capacity of 6 gallons. Another option is to purchase used outboard motor tanks at yard sales or on Craigslist.
The key components include a fuel transfer pump, a fuel supply line, and connectors between the external tank and the generator's internal tank. It is important to consider the hose length and diameter to avoid issues with fuel delivery. Additionally, the use of a non-return valve can prevent fuel overflow due to level differences between the external and internal tanks.
