Micro CoGen.

Hi Gang

Just wanted to provide an update to my build.  I just completed a major overhaul to correct some issues that have been nagging at me.

I could have avoided them if I had just read a little more on here.

1) The 1.5 inch square tube frame was no where near ridgid enough.  I have significantly strengthend the frame.  This has dramatically reduced vibration and has pretty much eliminated belt movement

2) I mounted the radiator horizontally (not as compact as before, but no leaking around the cap now. I can also add an expansion tank now)

3) I have updated the mounting / tensioning system by use 2 pieces of 1.5in square tube separated by a bolt width to provide the slots for belt adjustment.  This is far stronger that the lightweight bars I had for dogging it down before.

I am very happy with the arrangement I have now.  I have even created an idler assembly like Henry's.  I have not mounted it yet because I have to get a longer belt to make it work.

I would love to see some of the Cat / Perkins builds out there!


Thanks for all your help!

Chris

Hi guys

During a recent test run of my setup - Cat 0.5 driving a ST5 head, I noticed a problem.  I was getting 88V on each leg.  My ST has a AVR, so I removed the "voltage sense leads" and voltage came back up to 125V.  The AVR is still in the loop, but I suspect is just passing the Z winding voltage through.  I origninally had not planned on ordering one with an AVR at all.  It was just a surprise that it was in there.

My questions are:

1) Is 125V (@60.5HZ) too high?  - No Load
2) If I turf the AVR, How do I lower the voltage?  Or do I even need to?

If it safe, I will run it in it's current config.

Thanks for your help!

Thanks for the advice guys!  Bob  I went out and picked up a dial indicator with a magnetic base/arm.  It made it really easy to check the run-out.

Sure enough the problem was actually on the generator pulley bushing.  I must not have torqued it correctly.  Quick adjustment and belt movement has reduced by 80%.

Now the bottom of the belt "vibrates" by a coulple of mm rather than 10's of mm.  The top section of belt is equally stable. Is a couple of mm displacement acceptable?

I can still hear a mild / barely audible belt "squeak"  (even at no load).  Does this portend another issue?


One other interesting experience is trying to run furnace oil.  One of the local service stations has a pump that dispenses "furnace oil".

I picked up 5 gallons and proceeded to start the genset.  It ran very rough & produced more smoke.  It was almost like it was missing.

The only thing I can figure is that they were actually selling kerosene as instead of fuel oil.  I am going to draw some off my furnace tank and try running it to see what happens.

Does anyone else have any experience running one of this of other fuels?

On a final note, lets see some projects!  I need some more inspiration!

Thanks

Chris

Around 2400, actually only slightly less than it was set for when it arrived.  Maybe a half turn down on the governor setting.


Chris

Noise outside is VERY low.  I very happy with the noise level outside the barn.  Inside is a bit louder, but tolerable.

There is a bit of vibration, but again not excessive.  The front legs of my frame were just steel resting on concrete & the unit didn't wander around too much.  I have since place a rubber cushion under the legs.

I am pretty happy with the setup.  I just need to make up a dual idler pulley arrangement to reduce belt slap.


Chris

More Pictures and another comment... I discovers a really easy and inexpensive 1" to 1.25" hose adapter.  Went to home depot and bout a 1" barbed to 1" NPT adapter & a 1.25" to 1.25" NPT adapter.  I then slid the 1" threaded end inside the 1.25" and welded the seam.  You can see one in the pictures above the water separator.

More pictures

Here are some pictures of my first generator build based on an ST5 and Cat C0.5.  I used a serpentine drive from Mike Moneith.  I have added an automatic generator controller - GTR-168 from Tom at Georgia Generators.  I used a K&N air filter off ebay.  I made an insulated through-wall thimble that works really well.  The unit holds all of my loads really well.  The power output is stable and good enough to run everything I have.  Plasma TV and computers are fine running on generator power.  Fridges, Microwave and Well pump also are fine.  The only issue I currently have is excessive belt slap.

Chris

I am wrapping up my Generator build.  So far I am happy with everything.  The one kink I have not worked out is the belt tension.

I am using an 8 rib serpentine drive with a 6in & 8in pullet setup from Mike.  The Pulleys are about 16in on center, so that leaves me with a relatively short belt. I think it is around 54in.

I seem to be getting a lot of belt slap - an inch or so vertical movement  while operating.  I am reluctant to tighten the belt and harm the bearings in the engine. I have made sure the pulley faces are exactly true. 

Can someone describe a procedure to get the correct tension?  Should I add an idler?  This would not be too difficult.  I am driving a 5KW head and belt slippage does not seem to be an issue, although I only have 3KW test load.


I purchased the generator head and a GTR-168 controller from Tom at Georgia Generator, and he was great to deal with.  Mike Moneith provided a beautiful set of pulleys for what I thought was a VERY fair price.

I will post some pictures today in another thread.


Thanks for your help!

Chris