Perkins 402c-05 & utterpower PMG

[rcavictim]

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.

[mike90045]

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.

[flywheel]

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

[flywheel]

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

[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

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
                                                                                                   

[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

[mike90045]

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.

[Apogee]

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

[flywheel]

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

[Apogee]

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

[flywheel]

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

[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

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

[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

[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

[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