Micro CoGen.

Hi All,

I saw a video of someone else who did this and I thought it was a great idea.
I purchased a golf cart Starter/Generator and mounted it on the Listeroid.
There are two circuits to configure.
1] Starting circuit which uses a constant duty solenoid for the heavy pulling.
2] Charging circuit which is wired to the second set of windings in the motor.

Once the motor rpm exceeds approx. 1500, it starts back feeding to the battery.
The voltage regulator controls the field current in the second set of charge windings.

The wiring looks a bit messy because I just finished the job and have yet to tidy it up.
The standing battery voltage read 12.7 and when I started the unit, the charger was pushing 13.2 vdc.
I have not yet done any amperage reading so I don't know what the Generator is capable of.

https://www.youtube.com/watch?v=qbcbuygYJdM

Nice clean install! Have you tested to see how much load it puts on the engine? It looks like a bit different design than the system I have on an old Bolens garden tractor. Nice touch with the serp belt too.

Very nice install! Beats having a big meat grinder flywheel and starter setup. I was very impressed how nicely that little starter turned over the engine too. I never did get enough umph from my starter to crank Thumper over fast enough to start reliably (of course I killed my electric starter by increasing the start voltage to 24V on the 12V starter)(oh, but I didn't use decompression). It is also nice to have the self-charging setup - I always needed a separate charger which ran from the generator. Last but definitely not least - getting a standard starter properly meshed to the flywheel was always an issue - with your setup with the belt it is not an issue at all - nice!!!
Almost makes me want to play with the start system for Thumper .... but with an automated decompression setup.

Veggie:
Very nice!
I an electrically challenged, but can follow directions. Perhaps there are others in the same situation who admire (covet!) your installation. Would it be possible for you to post a wiring schematic? Where to connect what would be extremely helpful to such as myself.
Many thanks,
Hugh

I am sooo jealous of your setup. Please post a schematic so I can do the same.

Thanks

Bob

Be aware that there are various styles of Starter/Generators for Golf Carts.
Mine has separate "DF" and "D+" pigtail wires which connect to a voltage regulator. (See the red and green wires in the picture).
Some do not have these wires.
The one I purchased was listed as being for a Yamaha golf cart.

It was very confusing at first because I had no idea of the internals and wiring diagrams are virtually non-existent.
To compound the confusion, these can be wired to run backwards because some carts have a reversing two stroke engine and a reverse/forward solenoid which switches all the connections when the reverse lever is pulled.

It took me hours of digging through conflicting data before I found out how to wire this thing.
You can imagine the apprehension when I threw the switch for the first time, knowing that wires may glow red and smoke would end my project. 

For anyone wishing to travel this road, my crude wiring diagram is below.
CAVEAT: This worked for me, there are no promises or guarantees that this will work for you

BTW, today I gave it a strength test by flipping the start switch without de-compressing the engine.
It powered through the compression strokes effortlessly and the engine fired up.
I still prefer to de-compress and reduce the loads.

good luck,
veggie

Veggie, Is that a Yamaha regulator also?

Bob

Quote from: squarebob on June 12, 2013, 06:52:14 AM
Veggie, Is that a Yamaha regulator also?

Bob

The regulator is common on many golf carts.
Below is a picture of the regulator.
In my case, I bought a regulator for an EZ-GO cart.
As long as its 12 volt and has the DF, D+ and D- connectors, it should work.

Here...
http://www.ebay.ca/itm/Ez-Go-Golf-Cart-part-voltage-regulator-/190785229901?hash=item2c6baf944d

veggie

Also needed is a Continuous duty golf cart solenoid.
Unlike automotive starter solenoids which release after the engine has started, these solenoids stay engaged all the time to allow reverse flow for charging.
That's why my start/run switch is a toggle and not a spring loaded ignition switch.

They are available on Ebay under the description in the first line above.
http://www.ebay.ca/itm/Solenoid-Relay-Switch-Continuous-Duty-Golf-Cart-12-volt-/130597129264?hash=item1e68320c30&vxp=mtr

hope this helps,
veggie

Veggie:
Thanks for sharing all the detailed information with us. Very useful, will most likely give it a try, with any luck before winter when an electric assist would be greatly welcomed.
Cheers,
Hugh

Vegie,

I curious how much HP that starter/generator uses. Would you be willing to see how many KW your engine will produce with the belt on/off and report the difference? I know the one I have on a garden tractor soaks up a ton of power and runs hot, but the golf cart ones may be better.

Thanks Veggie. This type of info sharing is what makes this such a great forum.

Bob