Portable Loadbank Rebuild

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The old portable loadbank was getting a bit long in the tooth and due for an upgrade. First pic is the way It's been since I picked it up about 15 years ago. Second pic a close up of the very tired and warped resistor. Rated for 1000 amps but not for any decent length of time.Off to my favorite "special" hardware store for some newer heavy duty resistors. I tried to get four that were all a match but no luck. Ended up with two matching pairs almost identical and they carry a 250 amp test load with no imbalance issues. Temps are nearly the same on all four at various points. Attached ImagesMiller LegendMiller XMT 200Miller HF 251DMiller Spoolmatic 30AMillerTrailBlazer 250GLincoln LN 25Lincoln G9 ProLincWelder 225Lincoln Ranger 9Lincoln Ranger 275TJhttp://onanparts.com
Reply:Ready to start drilling the new mounting holes. One mounted, then two. Attached ImagesMiller LegendMiller XMT 200Miller HF 251DMiller Spoolmatic 30AMillerTrailBlazer 250GLincoln LN 25Lincoln G9 ProLincWelder 225Lincoln Ranger 9Lincoln Ranger 275TJhttp://onanparts.com
Reply:Im 20 so bear with me. What the heck is that?? More so what does it do?
Reply:All four mounted and ready for some testing! I put a 250 amp load on it and it barely got warm. Under 300 degrees at any location after 15 minutes.  Both meters need some attention cosmetically but function just fine so they will stay. Frame will get some fresh paint, Miller blue? Lincoln red? Next week a 500 amp load test is planned to see how it holds up. 200-300 amps continuous was my planned goal without having to use any fans etc. as it is a portable standalone unit. So far so good. Attached ImagesMiller LegendMiller XMT 200Miller HF 251DMiller Spoolmatic 30AMillerTrailBlazer 250GLincoln LN 25Lincoln G9 ProLincWelder 225Lincoln Ranger 9Lincoln Ranger 275TJhttp://onanparts.com
Reply:Originally Posted by slowlt1Im 20 so bear with me. What the heck is that?? More so what does it do?
Reply:Nice rebuild TJ.  Nice that the length was just right for the new resistors.I too would like to know if you're planning on a contactor and where did you relocate the shunt to for the ammeter?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by 7A749Try some Simichrome polish by Happich.It's the bee's knees for bringing dull meter faces back to life.Are you planning on putting a contactor on it?Looks like a winner to me!!
Reply:Well a contactor by any other name is still a contactor.  I'd say put a handle on that thing and ya got it made.THROW THE SECOND SWITCH!!! (Just saw the movie again last night.)MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Onan:I really like that project.  What was the source for the resistors and what are they called?  Are they just heat strips out of something?Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:Originally Posted by slowlt1Im 20 so bear with me. What the heck is that?? More so what does it do?
Reply:Originally Posted by DougAustinTXOnan:I really like that project.  What was the source for the resistors and what are they called?  Are they just heat strips out of something?
Reply:Do you reach in to the back to throw the switch or will it have an operating mechanism, plastic handle?MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by MarkBall2Do you reach in to the back to throw the switch or will it have an operating mechanism, plastic handle?
Reply:You could use a surplus 4-1/2" grinder side handle.   Give me a shout if you need/want one.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55You could use a surplus 4-1/2" grinder side handle.   Give me a shout if you need/want one.
Reply:Took the loadbank outside today for an extended test. Four hours at 250 amps and no problems. Did a search for Delta Star Electric and they have been around since 1908 manufacturing devices for the electrical industry. They were purchased by H.K .Porter in 1950 so the odds of them making the loadbank in the late 50's early 60's are fairly good. Maybe early 70's? Frame is all aluminum so instead of repainting it I think I'll strip it and buff/polish it out until it's nice and shiny. Delta Star is still in business making mobile substations and mobile transformers. Attached ImagesMiller LegendMiller XMT 200Miller HF 251DMiller Spoolmatic 30AMillerTrailBlazer 250GLincoln LN 25Lincoln G9 ProLincWelder 225Lincoln Ranger 9Lincoln Ranger 275TJhttp://onanparts.com
Reply:Originally Posted by 7A749Try some Simichrome polish by Happich.It's the bee's knees for bringing dull meter faces back to life.Are you planning on putting a contactor on it?Looks like a winner to me!!
Reply:Heres mine that has worked for me over the years.Also have an old Tad 1 pilot arc, also known as "pie warmer", , pulled the tranny out of it, lot lighter now. Attached Images
Reply:Nothin like some warm pie for lunch on a cold day. Did some cleaning on the ammeter today. Need to cut a new piece of glass as the original is pitted but it looks ok for now. Attached ImagesMiller LegendMiller XMT 200Miller HF 251DMiller Spoolmatic 30AMillerTrailBlazer 250GLincoln LN 25Lincoln G9 ProLincWelder 225Lincoln Ranger 9Lincoln Ranger 275TJhttp://onanparts.com
Reply:4hrs @ 250amps is a darn good test.  Nice rebuild.Interesting way of coming up with a load bank Billy.Nice job on the ammeter too!MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:TJ:That 4 hours at 250 amps would scare the hell out of me that I would blow my generator.  What welding machine/generator did you subject to the "acid test"?  By the way TJ, you supplied me with the pistons, rings, valves, gaskets and most of the decals for the Onan powered Bobcat 225g pictured in my avatar, a couple of years ago. DougMiller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:Originally Posted by duaneb554hrs @ 250amps is a darn good test.  Nice rebuild.Interesting way of coming up with a load bank Billy.Nice job on the ammeter too!
Reply:I got a vantage 500 here in northern california if you really want to put the ballz to her.   I KNOW it will pull 565 amps no problemVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Nice save.I don't like the load resistors out in the open though. Caged is the way to go. No sense in risking a shock or a short circuit.Why not have each load on a separate switch so  you could gradually increase load to the maximum? That's how we do it. Albeit on a 250kW Onan unit, we run 8hr load banking once a year. Gradual up, then gradual down.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Originally Posted by Joker11Why not have each load on a separate switch so  you could gradually increase load to the maximum? That's how we do it. Albeit on a 250kW Onan unit, we run 8hr load banking once a year. Gradual up, then gradual down.I guess you are right.I just ASSumed that one would use a load bank for more than just welders. I ASSumed he would be load testing generators too. I have a Ranger9 that could be loaded through the 240outlet or through the welding leads......my bad. Open box, think outside. I got it.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain