I believe I have rounded up enough parts and pieces to begin assembly of the Perkins and PMG. Pictures will be posted as we progress. flywheel
I just started working on the small Cat genset.
Can't wait to see your pictures.
Henry
Unable to post any pictures - upload file full, tried a bunch of times.
Quote from: flywheel on November 04, 2009, 09:46:48 PM
Unable to post any pictures - upload file full, tried a bunch of times.
I've been having the same problem with picture uploads today.
Quote from: rcavictim on November 04, 2009, 09:51:24 PM
Quote from: flywheel on November 04, 2009, 09:46:48 PM
Unable to post any pictures - upload file full, tried a bunch of times.
I've been having the same problem with picture uploads today.
I had this problem a while ago and it seemed that the maximum allowed space on the server was full, Admin adjusted (made bigger) it and it worked after that.
I'm not sure though if this is the same situation ???
Here is my plan for the Perkins/PMG. This little genset will be permanently located in my garage. I will assemble it in a compact as is practical unit to save floor space. The engine will be mounted within the frame to reduce height, Oil pan probably will be only one inch or so off floor.
Exhaust directed outdoors to muffler. Since it has a fuel pump a no fuel tank will be mounted on it, a small remote tank will be used, Lots of options here.
Serpentine belt driven with a short shaft with pillow blocks, flex coupling of my design and operated at a reduced rpm.
It is not intended to power my whole home but will provide temp power for short outages. I will also have lights to get a big genset on line outdoors if its dark outside.
flywheel
sorry for the inconvenience guys, i adjusted the size and we should be good to go again
still learning the ropes here
admin
Parts and pieces, flywheel
Quote from: admin on November 04, 2009, 11:08:52 PM
sorry for the inconvenience guys, i adjusted the size and we should be good to go again
still learning the ropes here
admin
Thank you! I was able to post my pictures.
Here is a bit more information and pictures of the utterpower 3kw PMG. This is the head that is to be belt driven by the 402c Perkins diesel. It is 3600 rpm and bidirectional. I'm looking forward to see this little unit up and running.
The utterpower PMG has a lot of features you just don't see in most generator heads. It has NO electronics of any kind - none! NO brushes, NO slip rings and NO rectifiers. This would mean this head is EMP proof.
It is a totally sealed unit, no dust or dirt can get inside, I believe you could squirt it with a hose and no water would enter. It has thick cast doghouse with a real rubber seal, the cable clamp even has a seal on it.
Inside the doghouse there is a terminal strip, all wires are clearly marked.
It has a unique patented cooling system, a huge 45mm HOLLOW shaft with cast iron fan attached. Air is directed through the hollow shaft for cooling.
This head meets ANSI standard C 84.1 from no load to full load.
flywheel
More PMG pictures.
Quote from: dubbleUJay on November 04, 2009, 10:11:54 PM
Quote from: rcavictim on November 04, 2009, 09:51:24 PM
Quote from: flywheel on November 04, 2009, 09:46:48 PM
Unable to post any pictures - upload file full, tried a bunch of times.
I've been having the same problem with picture uploads today.
I had this problem a while ago and it seemed that the maximum allowed space on the server was full, Admin adjusted (made bigger) it and it worked after that.
I'm not sure though if this is the same situation ???
Admin - make sure hackers are not filling all your space with naughty pics !
That will be one heck of a system.
I really wanted one of Georges PM's.
I wish they were just a tad bigger, and price with the shipping difference almost payed for my engine.
UPDATE - Perkins/utterpower PMG
As I mentioned in an earlier post this little genset will be indoors permanently and I will make is as compact as possible. The base/frame is made with 1.5" x 3.0" x 1/4" thickness rectangular tube. All fasteners are placed inside the tubing from the bottom so there are no bolt heads showing on the bottom of the frame.
Engine mounts are one piece instead of two mounts for each side of the engine. Its easier to make one larger mount than two small ones. The distance between mounting holes on the side of the block is only about 5 1/2". Mounts are made from 5/16" thick angle iron cut and drilled to size. The distance across the block (wide) at mounting points is about 7". These engines are pretty small and lightweight and are made of cast iron.
A note on engine mounting. The IDEAL way to mount most engines is to have the engine mount at or near the crankshaft centerline. My mounts project downward instead of straight out, not ideal but I'm building a compact unit so thats the way they need to be for this genset. I could make them straight out but it requires a higher frame at the mount points.
The oil pan plug is only 3/4" off the floor, I have reduced the overall heighth of the engine as much as I can. Oil changes will have to be done with the unit raised upon blocks. This can be done by hand as this is not a listeroid and the oil change schedule is every 500 hrs on the Perkins. flywheel
I like the way you made the mounts. The V cut in the mount reduces stress on the block.
Great Job!!
Henry
Perkins/utterpower PMG, more pictures.
Perkins/utterpower PMG, Radiator.
The radiator I will use is from surplus center and is the correct one for this engine. Its a nice three core made in Turkey, copper core, brass upper and lower, drain valve, bottom mount threaded nuts welded on, side mounts also. Its a a nice small compact well built radiator. About 13.5" wide and 15.5" tall. Upper and lower 1'' hose barbs and 35000 plus btu's.
There is NO radiator cap or filler on the radiator, I will probably solder something on the top for a bleeder and fill point.
The radiator must be raised about 5.5" to get it to the proper heighth for use with this frame. To raise the radiator I used short pieces of schedule 80 iron pipe. Inside the pipe is 3/8" all thread rod inside of a plastic sleeve to keep it centered within the pipe. The rod is double nutted on the bottom. There is also a large washer and nut on the Top end of the pipe. This nut is hidden within the lower rubber cushion. Two rubber cushions and another large washer are used. The upper end of the threaded rod is drilled for a cotter pin so the top nut cannot come off. This top nut is only tight enough to compress the rubber cushions slightly.
The welded on mounting nuts on the radiator bottom are metric thread, I drilled the threads out so the all thread rod passes through the welded on nut. There will be upper radiator braces as we get farther along with this project.
flywheel
More radiator pictures
Think you may need a shroud?
Quote from: WGB on November 15, 2009, 08:00:40 PM
Think you may need a shroud?
Yes - it will have a shroud, probably one of the last items to be installed after bracing, guards etc.
flywheel
So, here's a dumb question for you (and I do realize you are already where you are with this project)
Why not mount the radiator upside down using the side mounting flanges?
It would then leave the "bottom" hose connector pointing upward and you could use a 90 degree hose with a pressure cap for filling/bleeding the system...
Just a thought...
Great job so far! I'm learning from you as you go as I also plan to build at least one of these (I have 2 engines)
Also, I wonder if a fan shroud is going to be required. Several of the small engine installs that I've seen using Kubota engines haven't used a shroud... Might be worth trying without just to see how it cools...
Steve
Quote from: Apogee on November 29, 2009, 02:35:19 PM
So, here's a dumb question for you (and I do realize you are already where you are with this project)
NOT A DUMB QUESTION.
Why not mount the radiator upside down using the side mounting flanges?
THIS RADIATOR HAS VERY STURDY MOUNTS ON THE BOTTOM. IT ALSO HAS A DRAIN VALVE ON THE BOTTOM. THE SIDE MOUNT STUDS OR TOP FLANGE CAN ALSO BE USED, I BELIEVE THEY ARE ALSO USED FOR A SHROUD OR MOUNTING.
It would then leave the "bottom" hose connector pointing upward and you could use a 90 degree hose with a pressure cap for filling/bleeding the system...
THE PERKINS WATER OUTLET POINTS STRAIGHT UP SO IF THE RADIATOR IS UPSIDE DOWN IT WOULD REQUIRE A 180 DEGREE BEND TO CONNECT TO THE RADIATOR.
I WILL PROBABLY SOLDER A FITTING OF SOME SORT ON THE TOP TANK FOR A AIR BLEED AND FILLER, IT WON'T NEED A LARGE OPENING. THE UPPER AND LOWER TANKS ARE BRASS WITH A COPPER CORE, NICE LITTLE RADIATOR FROM SURPLUS CENTER -35000 PLUS BTU.
Just a thought...
Great job so far! I'm learning from you as you go as I also plan to build at least one of these (I have 2 engines)
Also, I wonder if a fan shroud is going to be required. Several of the small engine installs that I've seen using Kubota engines haven't used a shroud... Might be worth trying without just to see how it cools...
Steve
The holidays are over so its time to get back to work on the Perkins/PMG. I now have enough of my drive system parts to begin assembly.
The 402c Perkins diesel is a very small 2 cylinder engine, the flywheel is only 8 5/8" wide. A serpentine pulley will be bolted to the flywheel but the pulley will NOT be used to belt drive the PMG.
Mike Montieth made the flywheel pulley, this pulley also has three blind holes machined in it to accept drive bushings.
flywheel
Here we have the drive plate and short shaft. The drive plate has three blind holes to accept the drive bushings.
The short shaft is just long enough to accept two pillow block bearings and the sk bushing with pulley.
flywheel
The drive plate was also made by Mike Montieth, The short shaft was made at a local machine shop. Before final assembly I will weigh all the parts and pieces.
I do not want any side pull on the crankshaft so I'm using a short driven shaft with bearings. A belt driven generator requires a very tight belt especially if small diameter pulleys are used.
The short shaft also allows me to change pulley ratios to suit hp and rpm needs with the mini Perkins diesel. Using a short coupled shaft requires more parts, expense, time and planning.
flywheel
Nice I like the drive dogs.
Which pulley is driving what?
Starting to have some not so cold days here in N IL so I have spent some time in the garage on the Perkins/PMG.
The frame has been completed and painted, assembly has begun.
I have painted the flywheel, machined drive pulley/coupler half and drive plate. The pulley that bolts to the flywheel is used as a coupler half, no belt is used on this pulley. It is also machined for a SK bushing and 8 groove serp belt and can be removed and used as a pulley. I do not want side loading on the crankshaft so a short driven shaft will be used.
flywheel
The engine is ready to be installed on the new frame. It must be mounted square with frame and also level so the engine is not tilted up or down. The flywheel has been installed and is checked with a square to make certain the engine is not tilted.
flywheel
Pulley/coupler half bolted to flywheel and drive bushings installed. The red index lines on the bolts and parts are there so I can easily tell if any bolts have loosened.
The drive plate and short shaft have been installed, there is a gap of about .020 between the drive plate and flywheel pulley. I used three thin shims between the parts to set this gap.
flywheel
Excellent work.
Put this thread on my notify list.
I know I'll refer to this project, when I get to that point.
I jumped on the Cat label engine after SC ran out of the Perkins orange.
Randall
Quote from: flywheel on November 04, 2009, 10:26:37 PM
Serpentine belt driven with a short shaft with pillow blocks, flex coupling of my design and operated at a reduced rpm.
Speaking of homemade flex couplings, I have to tell one on myself. I was about 45 miles off shore on the boat when the water pump for the exhaust committed suicide. The identical replacement pump apparently was not. It was off just enough that the two shafts didn't line up. I took the flange coupling off both shafts and reversed them leaving the hubs facing each other and used a piece of rubber hose and hose clamps to connect them. Is that not redneck engineering at it's finest?
The genhead and its mounting plate have been installed today. I used a hinged plate instead of a slider, less pieces with hinges but either will work well. The mounting plate for the head must be square with the drive pulley or it will be very hard on the belt. Careful allignment is a must.
flywheel
Use a straight edge to allign pulleys, does anyone notice anything wrong with this drive belt? Engine mounting bolt heads have been drilled and safety wire added.
Having been around diesels for 40 plus years I have seen what can happen when bolts come loose and fall out. If this engine is left running unattended its a cheap insurance policy.
There is a lot left to do before this genny is in operation, belt tensioner, radiator, hoses, wiring, switches etc.
flywheel
Nice setup! What speed will the Perkins be cranking?
Look forward to the performance reports.
Kevin
You made lots of progress in a short time.
Nice setup.
Henry
Quote from: flywheel on February 12, 2010, 10:25:09 PM
does anyone notice anything wrong with this drive belt? flywheel
From a review of the pics of the pulleys and belt, I would say the belt needs to fill a couple more groove.
The current setup is what....6/8......only 75 percent of the available transfer of torque?
Randall
I guess would be able to get the torque applied with any belt, provided you could get it tight enough...
but the surface area is there....if it were me, I would fill up the other 2 grooves.
Longer belt life....less tension...less heat...less maint
Randall
I think the 6 groove belt will be fine for his application. The 3kw 3600 rpm PMG has much less inertia to overcome compaired to an ST5 or 7. I believe Flywheel will be installing a tensioner on the slack side of the belt. This will help the stabilization of the belt tremendusly. The extra wrap should increase belt life by a fair amount. If belt slap happens on the pull side all that needs to be done is to install a fixed idler to flex the belt up to 1/2". This will get rid of any bad belt harmonics. Once Flywheel gets it running he will know what is needed.
If Flywheel was running a single cylinder engine running at 1800 RPM's pulling a ST-12 like my S195 does then I would say the 8 groove belt is a must. And two idlers is a must. I done enough research and prototyping on this to feel comfortable enough to say Flywheel is probably fine.
Another good thing that flywheel did is he thought things through about the pulleys. Getting pulleys for 8 groove belts is often overlooked and if he does need to go to an 8 groove belt in the future he will have that option.
Good planning!!!
Henry
Flywheel,
What are you going to use to use the PMG for? Will you be using it to charge battery's?
What speed will the engine be running at?
Henry
Quote from: highwater on February 13, 2010, 01:14:14 AM
Quote from: flywheel on February 12, 2010, 10:25:09 PM
does anyone notice anything wrong with this drive belt? flywheel
From a review of the pics of the pulleys and belt, I would say the belt needs to fill a couple more groove.
The current setup is what....6/8......only 75 percent of the available transfer of torque?
Randall
Yes its a six rib belt on eight groove pulleys. I was unable to obtain a eight rib belt locally so I'm useing the six rib for now. This is a very short belt, only 38.75" od, I don't thnk there will be much belt bounce as close as the pulleys are.
flywheel
I think this would be a good time for somebody to post a thread on which side of a pulley to put the idler pulley so the idler just takes up the slack and increases contact to the driven pulley. I just don't have a good photo. but I have seen many installed wrong with owners being disappointed in the results.
Quote from: hwew on February 13, 2010, 07:40:16 AM
Flywheel,
What are you going to use to use the PMG for? Will you be using it to charge battery's?
What speed will the engine be running at?
Henry
The PMG will used as a temporary generator for power, I don't have a battery bank to charge. The engine will be operating at 3025 rpm with the pulleys as is. This was done intensionally so I can place a large load on the engine for some breakin hours and then switch to different pulley sizes.
Then the rpm will be reduced to around 2575 rpm with a pulley change and thats where it will probably remain.
flywheel
Sounds like a good plan Flywheel.
The engine should like running around 2575 rpm once broken in.
Henry
Belt tensioner, made with 3/8 all thread rod, long coupler, brass jam nuts and a spring clip. Simple and effective, the purpose of the clip is to keep the head from dropping down and causing damage if there should be a belt failure.
flywheel
Flywheel:
that sure is a sweet looking setup, and it is going to show well when you get it painted too.
lots of creative idea's and solutions there.
bob g
I think they are nice idea's. :)
How much longer before the test run? I don't want to miss the tests. :)
Henry
Quote from: hwew on February 15, 2010, 04:27:47 PM
I think they are nice idea's. :)
How much longer before the test run? I don't want to miss the tests. :)
Henry
I don't really know, thats the nice thing about being retired, I have no schedule.
flywheel
While spending some time in the garage today I managed to punch a hole in my brand new radiator for the perkins/PMG. Its a really nice little radiator from surpluscenter, three cores thick, brass upper and lower tanks but no radiator filler or cap.
Thats why I punched a hole in it on the upper tank so I could solder a brass fitting for a bleeder and hose for a small expansion tank
flywheel
It looks like you did a pretty good solder job there flywheel.
What type of pressurized expansion tank will you be using?
Henry
Quote from: flywheel on February 16, 2010, 06:45:09 PM
Quote from: hwew on February 15, 2010, 04:27:47 PM
I don't really know, thats the nice thing about being retired, I have no schedule.
flywheel
When I got home from my last day of work, I walked in the door and threw my watch and the calender in the trash can.
Now that I look back, I sort of regret throwing the watch away because it was worth a lot of money.
Quote from: rbodell on February 18, 2010, 07:59:14 AM
Quote from: flywheel on February 16, 2010, 06:45:09 PM
Quote from: hwew on February 15, 2010, 04:27:47 PM
I don't really know, thats the nice thing about being retired, I have no schedule.
flywheel
When I got home from my last day of work, I walked in the door and threw my watch and the calender in the trash can.
Now that I look back, I sort of regret throwing the watch away because it was worth a lot of money.
Was that the gold watch the company gave you when you retired? :D
Just a little hijacking of this thread:
Rcavictim,
That old RCA logo with lightning still existed on newer RCA TVs (only on the model sticker on back that they designed till last takeover reduced RCA to mere shell and no longer designs any (for last few years), just a re-branded TVs now.
Um, some people rather throw away to dump bad memories/stress. I know what they feel as my mom and I have been through bad times long ago.
Thanks, and back to the topic.
Cheers, Wizard
Quote from: rcavictim on February 18, 2010, 09:02:08 AM
Quote from: rbodell on February 18, 2010, 07:59:14 AM
Quote from: flywheel on February 16, 2010, 06:45:09 PM
Quote from: hwew on February 15, 2010, 04:27:47 PM
I don't really know, thats the nice thing about being retired, I have no schedule.
flywheel
When I got home from my last day of work, I walked in the door and threw my watch and the calender in the trash can.
Now that I look back, I sort of regret throwing the watch away because it was worth a lot of money.
Was that the gold watch the company gave you when you retired? :D
No I don't think I would have thrown that one away, but it was probably worth 3 or 4 hundred used.
Perkins muffler installation using the Cat/Cub Cadet muffler. This muffler quiets the Perkins diesel very nicely, the air intake is almost louder than the exhaust without the air cleaner installed. Muffler support must be attached to the engine block for support.
flywheel
The Perkins diesel has a very nice little fuel filter which attaches to the rear of the cylinder head. When the Cat/Cub Cadet muffler is used the fuel filter will be to close to the muffler and will need to be relocated.
I made a new mounting bracket using the old bracket and fastened it to the front of the cylinder head. The lifting straps were removed and the new filter bracket is installed using the mounting bolt holes from the lifting strap.
flywheel
That is one nice looking engine! Cant wait to hear how it works out for you ;D
Rob
Perkins first smoke. I have test operated the Perkins engine without a load to see how well my short shaft is going to work out. I'm very pleased, there is no vibration or runout.
I have had all the the fuel lines and filter off up to the injection pump. The fuel system had to be bled three times before the engine settled down and runs smooth.
This was a first run test with temporary fuel tank, wiring and radiator overflow tank. The Perkins holds a over little three quarts of motor oil and one gallon of coolant.
flywheel
Spent a little time on the Perkins/PMG today. Maybe I should say PMG's, the new 6kw model from utterpower.com arrived a couple of weeks ago.
Looks just like the 3kw PMG only a lot bigger and heavier and the terminal box is on top on the 6kw instead of on the side like the 3kw.
I'm going to make a temporary mount for it so I can apply a heavy load to the Perkins for some break in time on the new engine. Here are the pix of the 3 and 6kw PMG's side by side for comparison.
flywheel
Before the PMG's are put into service they should be tested to be certain they are wired correctly and both windings work. This is a very simple test to perform and it is done with a 12 volt automotive bulb or any small 12 volt bulb. For my testing I used a 12 volt rv bulb that screws into a standard pigtail receptical because thats what I had that was handy.
The PMG's are simple to test, there are only four wires and thats all. You can make the 12 volt bulb light with a quick twist of the pulley with your hand or foot. Three test were performed, one on each winding and one with both windings connected.
When the tests have been done the PMG can be put into service without any worry. Complete info on the PMG's can be found on the utterpower.com site on the PMG page.
The pix shows how a test is done with a 12 volt bulb and my temporary test setup useing the 6kw PMG. Tomorrow I may do some testing to see how the Perkins performs under a heavy load.
flywheel
Any other info on the 6kw head? I don't see anything on the web site.
Very nice project. Keep the updates coming.
Kevin
Nice! How much do the 3 and 6 kW PM heads weigh? Is it your plan to install the 6 kW head on this plant instead of the 3 kW unit? Are you wanting to sell the 3 kW head? I'm looking for a deal on a 3 kW head for my new 6.5 HP Launtop air cooled diesel to make a portable wall outlet.
Quote from: flywheel on March 07, 2010, 08:10:26 PM
Before the PMG's are put into service they should be tested to be certain they are wired correctly and both windings work.
Egads !! I'd think at those prices, The PMG's would come Certified to Work, they are not cheap clones.
Quote from: mike90045 on March 08, 2010, 10:42:23 AM
Quote from: flywheel on March 07, 2010, 08:10:26 PM
Before the PMG's are put into service they should be tested to be certain they are wired correctly and both windings work.
Egads !! I'd think at those prices, The PMG's would come Certified to Work, they are not cheap clones.
Mike, you mean to tell me you never check anything over before its put into service to see if there may be something thats not right?
flywheel
Quote from: rcavictim on March 08, 2010, 09:11:55 AM
Nice! How much do the 3 and 6 kW PM heads weigh? Is it your plan to install the 6 kW head on this plant instead of the 3 kW unit? Are you wanting to sell the 3 kW head? I'm looking for a deal on a 3 kW head for my new 6.5 HP Launtop air cooled diesel to make a portable wall outlet.
The 3kw PMG weighs about 60 pounds, 6kw weighs about 95 pounds. The 3kw PMG goes with the Perkins permanently and the 6kw goes on my Redstone permanently.
The 3kw PMG can produce over 4000 watts and that means a 8hp+ engine may be needed. If you have no need to make this much power then your Launtop should make a bit over 3kw.
flywheel
Quote from: V5CVBB on March 07, 2010, 11:46:32 PM
Any other info on the 6kw head? I don't see anything on the web site.
Very nice project. Keep the updates coming.
Kevin
There is not any information on the utterpower site for the 6kw PMG's, I believe
George B has a waiting list for the 6kw PMG's, I've had mine ordered for months.
The utterpower PMG's are in service in many different countries.
If you get no email reply from George he may be at his remote cabin in the mountains and will answer emails when he returns. I've heard people complain that he does not answer emails and this is probably why.
flywheel
Perkins engine breakin useing a breaker panel, 4 electric heaters, 4 kill a watt meters and the 6kw PMG. Engine was loaded from 2.5kw to 5kw for about 1.5 hrs.
The 6kw PMG can now be removed, pulleys changed, 3kw PMG belted up and engine operated at a reduced rpm.
flywheel
Quote from: flywheel on March 08, 2010, 07:50:44 PM
Quote from: mike90045 on March 08, 2010, 10:42:23 AM
Quote from: flywheel on March 07, 2010, 08:10:26 PM
Before the PMG's are put into service they should be tested to be certain they are wired correctly and both windings work.
Egads !! I'd think at those prices, The PMG's would come Certified to Work, they are not cheap clones.
Mike, you mean to tell me you never check anything over before its put into service to see if there may be something thats not right?
Some things (most) from overseas, get detailed. Others, when paying top dollar, I'll assume are serviceable, and carry a warranty. I bought a pallet of 1st quality PV cells, I did not re-test each one. If I'd bought blems, I would have. Some things I'm investing my $ instead of my time.
Flywheel,
Nice job thus far!
How did the little Perkins do at 5kw? Was she smoking or still running clean? I'd like to know what the max that these are able to generate in real life is.
Also, did you do any fuel consumption testing?
Finally, how's the noise when running? Horrible or easily lived with? I'm looking at the same muffler setup for mine, hence why I'm asking.
Again, beautiful work!
Steve
The exhaust is clean at 5kw, and engine at 3030 rpm with the pulleys used. The Perkins engine is rated at 13.7 hp @ 3600 rpm and should produce 6.5kw.
No fuel consumption tests have been done yet. When I change the pulleys and operate at about 2575 rpm I will run a few fuel consumption tests.
The Cat muffler works very well, the intake is louder than the exhaust without the air filter installed. I have a new Donaldson air filter assembly that I will install on this engine whenever I get around to it.
flywheel
Flywheel,
Thanks for the info!
I was planning on mounting my genhead over the top of the engine to save space. However, now that I've seen yours and where the battery sits, it makes sense to lay it out as you did. Mind if I mimic your design?
I haven't fully decided on running the stub shaft like you did, but I really like how it turned out. Should live a very long time I would think.
One design question - if the engine will do 6.5 kw @ 3600, I would guess somewhere around 5 or 5.5 kw @ 2500, why not run the larger gen head instead of the smaller one? Just curious about why you chose the size head that you did?
Again, beautiful work!
Regards,
Steve
O my gosh, its been nearly 10 months since I have updated the Perkins with utterpower PMG. Looks like I have a lot of catching up to do.
The Perkins with the utterpower PMG is completed and has been for a long time. I will be posting new pictures as soon as I have a chance to take and post them.
flywheel
Quote from: Apogee on March 22, 2010, 11:07:56 PM
Flywheel,
Thanks for the info!
I was planning on mounting my genhead over the top of the engine to save space. However, now that I've seen yours and where the battery sits, it makes sense to lay it out as you did. Mind if I mimic your design?
I haven't fully decided on running the stub shaft like you did, but I really like how it turned out. Should live a very long time I would think.
One design question - if the engine will do 6.5 kw @ 3600, I would guess somewhere around 5 or 5.5 kw @ 2500, why not run the larger gen head instead of the smaller one? Just curious about why you chose the size head that you did?
Again, beautiful work!
Regards,
Steve
Steve
The Perkins does not use a stub shaft. It uses a seperate very short shaft supported by two pillow block bearings. The short shaft and its drive plate are connected to the engine only by the three rubber bushings which act as a flexible coupler.
There is no crankshaft side loading with this setup.
Why only a 3 kw head - this genny is designed to operate at 2650 rpm with a 7 inch pulley on the shaft and a 5 inch pulley on the PMG.
At 2650 rpm the perkins will make over 10.5 hp, have better fuel economy and last longer. It is a small genset that will be located in my garage. The PMG will make over 4 kw continuous without overheating and surge more than 5.5 kw.
It is not intended to be a full time whole house genset. Its main purpose is for short duration outages and most importantly it gives me light and power to get a large whole house outdoor genny going while still having power indoors.
Attached are a couple of pix of the rubber drive bushings and related parts.
flywheel
Perkins/ PMG with 7 inch pulley on shaft and 5 inch pulley on the PMG for operation at 2650 rpm.
The black tape with the yellow reflective squares on the drive plate and PMG bushing are for checking the rpms with a digital tach.
flywheel
Country boy engineering! This is how I make the drive bushings for the Perkins/PMG. Simple, cheap and effective. After about 50 hours of run time I disassembled the coupler to see how well the bushings hold up.
They look great with only the glaze broken on the outer rubber tube. The bushings are made from 1 inch od dishwasher hose with a 5/8 wood dowel inserted inside and cut to length. You can see a pix of the bushings and wear after about 50 hours of use a couple of posts back.
flywheel
See thru belt guard allows me to see the complete drive system. Try making this with a stick welder, thats all I have. Made from a old fridge shelf.
flywheel
Fuse box/disconnect switch, 240vac and 120vac recepticals I could not find a small breaker box locally so I used plug type fuse box.
flywheel
I use a battery disconnect switch to supply 12vdc power to the control panel. When the genset is not in use all 12vdc power is turned off and disconnected.
flywheel
The control panel.
KISS - the simpler the better. There are no electronic parts anywhere on this genset including the PMG. It is basically setup the same way the as the warning system lights on you car. Sometimes referred as idiot lights.
To start the genny turn on the disconnect switch at the battery.
Turn on the fuel, controlled by a toggle switch that powers up the fuel shutoff solenoid.
Turn on glow plugs if needed. This is done with a dpdt spring loaded toggle switch, you must hold the toggle in the on position. This switch sends power to a solenoid which then turns on the glow plugs.
Turn this same switch to the start position to activate the starter solenoid, it is also spring loaded and returns to the off position when released.
To stop the genny turn off the fuel shutoff solenoid with the fuel toggle switch and turn the battery disconnect switch off.
The pix is of the solenoid that operates the glow plugs.
flywheel
Beautiful job Flywheel!
I agree with the KISS principle and this is a very nice example of it.
I hope mine come out as well once I get started on them.
Nice work!
Steve
It still say it's red.
q.
Nice Job
Modern design.
Compact as I could make it.
30" long, 24" wide and 25" high
Estimated weight - 325 pounds.
No solid state electronic parts.
Automatic low oil and over temerature shutdown to be added.
flywheel
Nice belt cover ,shopping cart?
Quote from: wiebe on January 31, 2011, 05:14:22 PM
Nice belt cover ,shopping cart?
No - shelf from a fridge.
very very nice!
i like it,
hey you wanna start building gensets?
:)
bob g
Quote from: wiebe on January 31, 2011, 05:14:22 PM
Nice belt cover ,shopping cart?
Ah, a great use for those rusty shopping carts down in the creek. I'll have to thank some of those scalawags who drug them all the way out there.
Generator Grounding
This is what I use to connect the generator to a suitable ground. This is a very important item that belongs on your generator especially if its used a stand alone generator.
When your generator is used as a stand alone generator ( not tied into your main breaker panel ) this ground wire becomes very important.
It will protect you from being electrocuted if there is a electrical short where the engine, frame or other parts becomes energized. It will send the current to ground an protect you from electrical shock if you touch any part of the generator.
All store bought generators have a lug for grounding, if you build your generator you must include a lug for grounding.
End of this weeks safety meeting, please sign the attendance sheet.
flywheel
flywheel:
you had me sold right up to the grounding thing!
whatcha trying to do? take all the excitement out of making sparks?
:o
very good point, that is probably often overlooked by a few of us while hastily getting the power going.
bob g
Diesels are Chick Magnets - heres proof!
I have built the Perkins/PMG to be very user friendly. Here is Mrs flywheel starting it up.
It only took a couple of lessons and she and she can have it up and running making power.
If I'm not home and power is out she can start this little genset and have power. She can't start a listeroid but she can start the Perkins with electric start. Her only complaint is that the exhaust stinks.
flywheel
I was over at UP earlier and saw your handiwork posted up front and center!
Your now an AE celebrity ;D as well as Mrs. Flywheel.
Question, does the PMG have any 'cogging' when you rotate the shaft.
Ben
Quote from: injin man on February 07, 2011, 07:27:24 PM
I was over at UP earlier and saw your handiwork posted up front and center!
Your now an AE celebrity ;D as well as Mrs. Flywheel.
Question, does the PMG have any 'cogging' when you rotate the shaft.
Ben
[/quote
There is cogging with the 3 kw PMG when the shaft is rotated by hand without a belt attached. On the 6 kw utterpower PMG the cogging is barely noticeable.
flywheel