How to Size a Generator?

Portable,
Backup & Standby for Home &
Commercial Applications
A generator is a suitable alternative to provide electric power where and when
you need it in case of power failure and emergency power outage, blackouts,
construction sites, camping, outdoor and RV (Recreational Vehicles)
applications etc.

A generator can be hooked up to the main service panel via ATS (automatic
transfer switch). You may do so by obtaining a building permit with the help of
a qualified and licensed electrician. Multiple generators are available for small,
medium and large potions the the type of generator (such as portable,
backup, standby for home or commercial) depends on the load requirements
and applications.

In the following post, we will show how to find the suitable size of generator
for home applications for different scenarios like whole or selected circuits and
types of loads etc.

How Much Size Portable Generator Do I Need

for Home Applications?
Generally, a portable generator is preferred for small and selected load points
in a house. No matter if you go for selected circuits or whole loads connected
to the main panel, you will have to find the wattage rating of all appliances and
add them to get the estimated value of the generator in kW.

Keep in mind that most household appliances like general lighting circuits are
resistive loads and you may add the exact value of these kinds of loads. In
case of high inductive loads (such as compressors, electric ranges, air-
conditioners etc.), the starting current and wattage are bigger than the running
amperes and wattage. No worries, we will do it in the next following solved
example.

Keep in mind that alternators and generators are always rated in kVA (kilo-
volt-amperes) but in our examples, we will express the rating of the generator
in kW (kilowatt) as we use it on load side where most of the home appliances
are rated in watts.

To know the wattage rating of a device, simply refer to the nameplate data
printed on it. If not available, you may multiply the voltage to the amperage to
get the wattage value. For example, the wattage rating of a 120V, 0.8A fan is
96W i.e. (120 volts x 0.8 Amps = 96 Watts).
In short, you may use the following formula to calculate the wattage rating of
an appliance.

P=VxI

Where:

 P = Power in Watts
 V = Voltage in Volts
 I = Current in Amperes
In simple words,

Power in Watts = Voltage in Volts x Current in Amps

Watt = Volt x Amps

VA or W is the basic unit of electric power. For higher values, we use k (kilo)
e.g. 1000W = 1kW. You may simply find the W from the A and vice versa
using the Watts to Amps Calculator & Amps to Watts Calculator respectively.

Sizing a Portable Generator

Now, let’s see a solved example about sizing a portable generator according
to our needs.

Example:
What is the suitable size of portable generator for the following household
appliances?

Small Load

 4 No of Fans each of 80W = 320W

 4 No of LED Light each of 25W = 100W
 2 No of LCD TV each of 120W = 240W
 1 No of Laptop having 110W = 110W
 2 No of Phone Charger each of 25W = 50W
 Dishwasher: 120V x 8A = 1200 VA = 0.96 kW
 Garbage disposal = 120V x 6A = 960VA = 0.72 kW
 Other general small appliance load = 1.5 kW
Total Small Load = 320W + 100W + 240W + 110W + 50W + 960W + 720W +
1.5kW

Total Small Load = 4 kW

Large Load

 Air-conditioner: 240V x 15A = 3.6 kW

 Electric range: 240V x 25A = 6 kW
 Electric heater: 240V x 30A = 7.2 kW
 Clothes dryer: 240V x 10A = 2.4 kW
 1HP ( 746W) Air compressor (L-Type motor) = 120V x 5A x 6* = 3.6 kW
 Circular saw (G-type universal motor) = 120V x 5A x 3* = 1.8 kW
You may have noticed that we have multiplied x6 and x3 with the 1HP L-type
motor and G-type universal motor. This is due to this kind of motor taking very
high initial starting currents and running smoothly with normal load current
when achieving the running speed.

In addition, We must take the demand factor into account as we know that all
the appliances won’t run at once continuously. For example, a heater and air-
conditioner won’t be operated at the same time. In this case, we will count the
highest rated appliance (electric heater in our case as its wattage rating
(7.2kW) is more than the air-conditioner which is 6kW). (NEC® Article
220.82(C)). And the allowable demand factor for 7.2 kW electric heater is 5.76
kW (NEC Table 220.55). Electric range is excluded as it runs only for a short
time period.

Demand Factor for Small Load

 Electric range: = 3.6 kW

 Electric heater: = 5.76 kW now ( after demand factor 7.2 kW)
 Clothes dryer: = 2.4 kW
 1HP ( 746W) Air compressor (L-Type motor) = 120V x 5A x 6* = 3.6 kW
 Circular saw (G-type universal motor) = 120V x 5A x 3* = 1.8 kW
Total Large Load After demand factor = 3.6 kW + 5.76 kW + 2.4 kW + 3.6 kW
+ 1.8 kW = 17.16 kW.

Similarly, no one uses all the electrical connected load at once like fans,
lighting points, hair-dryers, washing machines, electric ranges etc. According
to (NEC Table 220.42), the first 3kVA or kW should be rated at 100% while
remaining load can be rated at a demand factor of 35%.

Demand Factor for Small Load

Total Small Load = 4 kW

 The first 3 kW at 100% = 3 kW

 Remaining 1 kW (4 kW – 3 kW) at 35% = 350 W
Total Small Load After demand factor = 3 kW + 350W = 3.35 kW.
Now the total load in watts (small load + large load) = 17.16 kW + 3.35 kW =
20.51kW

20% Future Expansion

Finally, add a 20 to 25% future expansion load to the calculated value. This
way, you may smoothly connect an additional load in the future to the
generator. Moreover, this extra large capacity will easily handle the voltage
spikes and transients etc. In addition, it will expand the life of the generator as
running a generator at 100% rated load continuously will shorten the useful
life of the generator.

In short, by adding an additional 20% wattage capacity to the rated generator:

 You can add additional load in the future without affecting the efficiency of
the generator.
 It will easily handle the transient voltage and sudden load spikes during the
operation.
 It will reduce the generator from unwanted noise.
 It will expand the life expectancy of the generator as running the generator
at 100% rated load simultaneously will reduce the lifespan of the generator.
By doing so, the 20% extra wattage of the total calculated value of 20.51kW

20.51kW + 20% = 4.1 kW

Now the the total required size of generator would be:

20.51kW + 4.1 kW

Required size of the generator: 24.61 kW.

The next available and suitable size of generator is 25 kW.

Sizing a Commercial Generator for Standby &

Backup Power
A portable generator also known as emergency generator set as the name
suggests, provide power when and where needed in case of emergency
blackout. On the other hand, backup and standby generator are always
connected to the main panel via ATS switches and automatic electronics
circuits where they automatically restore the electric power within seconds
when main power is not available from the electric power service providers
due to multiple reasons.

Commercial generators are used for large scale applications and places
where the business operates 24 hours a day like resorts, restaurants and
retailer places, gas filling stations, bank and financial institutes, security and
hospitals, manufacturing plants etc.

Keep in mind that large scale commercial backup generator require a proper
designing and installation plan and compliance with National Electrical Code
(NEC) requirements (700, 701, 702 and 708). As the applications and
operations of same devices are different for different users and costumers
depends on system requirements, a commercial backup power generator may
be sized using the following methods.

Measurement of Full Load kW Capacity

This is quite a simple calculation based method. Just pick an ampere meter
(or clamp-on ammeter) and measure the full load current in amperes of each
leg (electrical service entering to the main panel) during the peak usage. Just
add all the three values to get the total amperage for the service facility.

If the wiring system is three phase, just divide the total measured amperes on
3. Otherwise, divide the measured amperes by 2 for single phase. Now,
multiply the resulting amperes by the supply voltage (e.g. 120V, 230V or 240V
etc.). This way, you will get the wattage rating required by the facility. Now,
divide by 1000 to get the size of the generator in kW rating. Finally, add 20%
additional wattage capacity to the calculated value. This is the estimated and
needed size of the generator required for the desired facility.

Estimate the required generator capacity by taking full-load current

measurements during peak usage at the service panel. Use a clamp-on
ammeter on each leg of the electrical service and add the measurements
together. This provides the total amps used by the facility.

Example:
What size commercial generator do I need in the following scenario.

Service Panel, Single Phase, 240V

 Amp in Leg 1 = 175A

 Amp in Leg 2 = 165A
Solution:
Just add the two values and divide by 2.

175A + 165A = 340A

340A ÷ 2 = 170A.

As the service voltage is single phase i.e. 240V (US-NEC), just multiply the
average value of measured current.

170A x 240V = 40,800 W

Just divide by 1000 to get the kW rating

40,800 W ÷ 1000 = 40.8 kW.

Now add the 20% additional capacity for future load.

40.8 kW + 20% = 8.16 kW.

Now add the calculated wattage rating plus future expansion load of 8.16 kW.

40.8 kW + 8.16 kW = 48.96 kW

The next available right size commercial generator is 50 kW. Follow the
NEC articles (700, 701, 702 and 708) while calculating the full load kW for
sizing a commercial generator.

Full Load Capacity From Utility

This is the easiest way to find the size of commercial generators especially for
businesses operating 24 hours a day. To do so, just evaluate and analyze
the utility bill from energy providers. You may find the peak demand factor
and power usage over monthly and yearly bases. Just pick the highest peak
demand value in kW and add 20% as additional capacity for future load. This
is the estimated value of kW rating of the required generator.

Full Load kW Capacity of Extensive Motor

In this method, select the largest size of motor among others which are
frequently ON and OFF for different applications. You may multiply the
amperage of this large motor to its rated voltage to determine the wattage
rating.

Now do the same e.g. find the wattage rating of small motors and non-motors
loads and add them all. Finally, add a 20% future expansion capacity to the
calculated value as shown in the first example. Divide the calculated value by
1000 to get the kW rating of the generator. This is how they size a commercial
generator using the full load capacity of an extensive motor.

Measurement of Square Foot

This method is commonly used by retail applications for sizing a commercial
generator.

In this method, they add 10 watts per square foot for retail applications while 5
watts per square foot for other general and commercial applications. For
example, to determine the size of the generator:

 Retail Applications = 75 kW + 10 W per ft2

 Other general applications = 75 kW + 5 W per ft2