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New guy questions on generating power


By pumkindrvr, Section Homebrewed Electricity
Posted on Fri Mar 26th, 2004 at 01:32:51 PM MST
unknown

A few questions from a newbee. I just bought some land in south west
texas to build a home on. It is too far to get city electricity so I have to get Off the Grid. I have a few questions for you experts.

Can a Chicago Electric generator(http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=41012)
be used with human, wind, etc power, or does it have to have a consistant speed as with a gas engine.

If car alternators can produce up to 120 vdc, how do you convert it to ac, without a large investment for an inverter.

What would happen if you plug a 120 vac motor like a drill, circular saw, or cement mixer into dc, say you hooked 10 car batteries together?

What would you use a 35 amp bridge rectifier or a 40 amp diode for?

Hope these questions are not to dumb.
Thank You,
Rob

New guy questions on generating power | 15 comments (15 topical, 0 editorial)

Re: New guy questions on generating power (none / 0) (#1)
by hvirtane (hannu_markus_virtanen(at)yahoo(dot)com) on Fri Mar 26th, 2004 at 02:47:29 PM MST
(User Info) http://web.archive.org/web/20050404022706/www.cc.jyu.fi/~hvirtane/cooker/

If car alternators can
produce up to 120 vdc,
how do you convert it to ac,
without a large investment
for an inverter.

Actually car alternators are
producing basically first AC.
AC coming out the coils is
then put through a rectifier
and converted into DC.

You can get even 230 V AC out
of a normal car alternator,
if you will drive it
without any regulator.
The problem with this AC is
that the frequency is not suitable
for most normal appliances
built for grid electricity.

If you are planning to build
an engine generator
utilizing a car alternator
it is probably best
to use the generator
to charge batteries and
then use an inverter to run
the appliances.
Or you might build a 12 V
DC electric system.

- Hannu



Re: New guy questions on generating power (none / 0) (#2)
by Hank on Fri Mar 26th, 2004 at 02:52:37 PM MST
(User Info)

I'll try to field some of your questions.
  1. Generator is probably a constant speed. It requires 16 HP so I doubt a human or for that matter wind will be of any value.
  2. Car alternators are AC (hence the name alternator) Ac is converted internally to DC using diodes. I'm not sure what the frequency is of a car alternator at 2000 rpm or if it can be used for AC by bypassing the diodes. To convert from DC to AC you use an inverter.
  3. If they have universal motors then they will work (drill, saw, etc.)
  4. Bridge rectifiers are used to change AC to DC. Rectifiers use diodes. A single diode can have many uses. Usually used for blocking current from going bacwards. For instance, if you used a DC motor as a generator and it was hooked up directly to a battery once you stopped turning the generator the current would flow back into the generator and it now would be a motor and would turn. A diode can be placed in the circuit to prevent the current from flowing back, like a check valve.
  5. There is no such thing as a dumb question!
Have fun,
Hank



Re: New guy questions on generating power (none / 0) (#3)
by bkrahmer on Fri Mar 26th, 2004 at 02:58:44 PM MST
(User Info)

As much sun as you get down there, I'm wondering why you wouldn't go solar.  Personally, I would go solar with a backup LP generator, along with gas appliances.  Since you have the luxury of starting from scratch, you have the ability to design your system to be as efficient as possible, which will save you money in the long run.  Don't forget lots of insulation and earth cooling (heat pump).  Solar hot water heating would also be ideal in your location.  If you have a small budget, it may negate efficiency, unfortunately.



Re: New guy questions on generating power (none / 0) (#4)
by pumkindrvr on Fri Mar 26th, 2004 at 03:06:54 PM MST
(User Info)

Eventually, I plan on going solar. Right now I'm just looking for a cheap way to run my ac cement mixer. Inverters large enough for it are expensive. Any ideas where to get a 12 volt cement mixor motor, 1/3 hp, 1500 rpm?
Thanks



Re: New guy questions on generating power (none / 0) (#5)
by hvirtane (hannu_markus_virtanen(at)yahoo(dot)com) on Fri Mar 26th, 2004 at 03:26:18 PM MST
(User Info) http://web.archive.org/web/20050404022706/www.cc.jyu.fi/~hvirtane/cooker/

Right now I'm just looking for a cheap way to run my ac cement mixer.

Recently with a friend of mine
we solved the same
problem with a Honda engine generator
producing AC current.
It worked perfectly even if we were
suspecting that there
wouldn't be enough power for the mixer.
You might rent such a machine
for the purpose.

Another way would be to get
a small 12 V DC engine
in the place of the original AC motor.
From a washing machine, maybe.

Still another
way would be to use
a cement mixer, which is
without the ac motor
and use your muscles or
somebody else's muscles.
Some tens of years ago
I did that job a lot.

You might be able to use
some kind of belt drive
from an engine
or even from your car wheel
to drive the mixer, too.

- Hannu

[ Parent ]



Re: New guy questions on generating power (none / 0) (#6)
by drdongle (Dr.Dongle1@juno.com) on Fri Mar 26th, 2004 at 04:17:52 PM MST
(User Info)

Why not replace the Ac motor with a gas engine? far simpler and more reliable.
Dr.D
Carpe Vigor, Dr.D
[ Parent ]


Re: New guy questions on generating power (none / 0) (#8)
by Homebrewed12vdc on Fri Mar 26th, 2004 at 09:10:02 PM MST
(User Info)

A lot of people have converted old belt driven cement mixers and table saw to run of from a small engine like a 3 to 5 horse briggs and straton. Just some food for thought. You could then just buy a 2000 watt inverter and hook it on your vechile and let that run to power all other smaller electrical loads, ( lights, skill saw, jig saw, etc.)

[ Parent ]


Re: New guy questions on generating power (none / 0) (#7)
by John II (jjones2(at)inetvisions.net) on Fri Mar 26th, 2004 at 08:47:43 PM MST
(User Info)

Rob: We have a large 12v dc PV system, and now are building an even larger 120 vdc PV system. I have a handfull of thoughts I think might be of value for you.

Pick up your phone and dial 800-488-3407 and ask them to send you their free catalog. It's has alot of quality surplus DC motors and other items at a fraction the cost of other places. It's great for A.E. people. ( Alternative Energy )

Their web site is: www.surpluscenter.com

For a few dollars on a surplus dc motor you could run your cement mixer on 12vdc 24vdc or even 120vdc. A gas motor is still a viable option as mentinoed eairler.

Also often Ebay has excellent prices on DC motors. Try to stick to PM DC motors ( permanent magnet) are much more effecient then other typs of dc motors. A 24vdc pm motor will run just fine at 12vdc, but produce 1/2 the power.

Also spend a few $$ and subscribe to HomePower magazine : http:www.homepower.com  You can also for just a few dollars purchase all of their back issues on a CD. They contain tons of helpful info.

Also this Forum here is a true blessing with alot of good folks welling to help on it, as you are all ready finding out : )

In HomePower magazine there are several vendors that sell their large catalogs for $10 each or so. Not only do they have items for sale, but they also have alot of charts to help you plot what size system you should eventually have... such as a 12v system, 24v, 48v or higher. THIS IS CRITICAL !!!  AS I learned the hard way : (

Here's why.

You won't realize it at first, but whatever voltage you go with, If you are not careful.... you will slowly add items. Before you realize it, you'll have a fairly large investment in those items, and it will make it hard to change to a higher voltage because of your incurged high investment into all the lower voltage items that you have purchased.

There are alot of trade off's with different voltages. There are tons of items available for 12volts But when you start demanding more power... your battery cables finally grow to solid copper ones the size of a garden hose ! I'm running "0000" and this stuff is huge and expensive.

Moving upto 24v your wire size is reduced about 4 times in size, yet runs the same amount of energy down them. There's getting to be quite a bit of items that will run right off of 24vdc. Larger commercial 24vdc inverters are often actually less costly per output then their 12v counterparts.

  1. volts is becoming popular with large systems. Voltages higher than this can be leathal if you come into contact with it. But 48 volts will usually just tingle, but not harm you. ( I say usually.. it still pays to practice saftey at 48v )
  2. vdc to 48vdc are all dangerous as far as possible explosion or burns are concerned. A wrench accidently droped across the post of large battery banks can instanty turn them white hot... That's not good if you are still gripping it !
In choosing the right voltage, PV pannels can eaisly be rewired to just about any voltage. Some wind generators homemade and boughten can be re-wired  to produce between 12,24 and even 48v. But your expensive High effeciency refrigerators that you'll eventually probably have 5 years down the road, custom dc ballast floresent lights in ever room can make it harder to upgrad to a higher voltage should your system size get big enough that begs you to upgrade to higher voltages.

120 vdc is used in really large systems (usually commercial ), the voltage is very dangerous... and Inverers are ultra expensive.. usually starting out at $6,000.00 ( this is the current situational problem I'm trying to deal with.. I can't afford that.. and I really need one ) Advantages are, that most good commercial brush type power tools are rated right on their lable to run directly off of the 120vdc. Wire size is like normal house wiring and very convenient and nice to work with.

We built a new house on 120vdc. We built two large wood boxes with handles on the ends. Each box held six 12v deep cycle boat trolling batteries ( 60 volts per box )We rigged cables to plug both boxes togeather to produce 120vdc at the job site. We ran a table saw that had a brush motor on it, and all power tools. At night we brought them back to a power grid and re-charged them. It was nice quiet silent power. But doing this can kill the power switch on all of your tools, unless they are rated to run on 120vdc. DC arcs long distancs and will not eaisly break the arc like ac power does.

I also helped build a house using a one lung 16hp diesel ac generator... Trust me.. no one wants to go through the agony !!! Nothing like having it pounding away noisly all day long while you run a tiny jig saw ! haha

Bottom line... try to plan into the far future, how much power you hope to produce and use. Then plan your system to that voltage... this is especially critical concerning your appliances, and loads.

There is a electronic device known as a buck booster, and also special solid state switching power supples that are being discussed on this form, that might allow you to boost your low voltage wind machines upto a higher system voltage.

If you get time Rob, Email me... I'd be happy to discuss more... and I'd like to know more about your local... I bet you have alot more sun and wind then we do here. I'm living in S.W. Missoui.. and we really don't have much sun, or wind.. or hydro.. kind of a poor spot for A.E. as compaired to other areas..

Hope some of this helps...

John II



Re: New guy questions on generating power (none / 0) (#9)
by TomW on Sat Mar 27th, 2004 at 05:28:16 AM MST
(User Info)

John;


You won't realize it at first, but whatever voltage you go with, If you are not careful.... you will slowly add items. Before you realize it, you'll have a fairly large investment in those items, and it will make it hard to change to a higher voltage because of your incurged high investment into all the lower voltage items that you have purchased.

All I can say is that is dead on the mark. I locked myself in to 12 volts in the begining and pretty much have regretted it from the first month forward. My panels, controller and batteries can be used at higher voltage but my trio of inverters keep me locked in to 12 volts when I would have gone at least 24 volts had I known then what I know now.

Cheers.

TomW

"Education consists mainly of what we have unlearned."--Mark Twain
[ Parent ]



Re: New guy questions on generating power (none / 0) (#10)
by pumkindrvr on Tue Apr 6th, 2004 at 08:59:21 AM MST
(User Info)

Hello
 I have some more questions. If most inverters and dc accessories run off 12 volts, what are some reasons for having a higher voltage system?

 Can either an older type car generator or an alternator be used as a 12 motor for powering things like bycycles or cement mixers?

 I purchased a 16 page booklet titled "Alternator Secrets", mostly out of curiosity. One section I found interesting claims you can build a 120 volt, 60 cycle alternator by using an induction motor from a washing machine. You would have to run the motor faster than the nameplate rpm to get 60 cycles and you might have to hit the coils with a dc pulse to get it to start generating. This should produce enough power for anything from a tv to refrigerator. Not knowing that much about electric motors, etc, I would like to hear some opinions on this. It sounds to easy to be true.

As for my quest for a 12 volt cement mixer motor, I just ordered one from Surpluscenter for a very good price of $30. Now my problem is finding a pully to fit the 5/16 diam. shaft. Here are the specs: 12 volt DC, 3600 RPM, 29 amps, 250 watts (1/3 Hp). Duty cycle 30 on, 60 off. Reversible. Shaft 5/16" diam.x 1" w/flat. Four tapped face mounting holes. Size 4 1/4"diam.x 8". Shpg wt 12 lbs. What does that part about duty cycle mean?

Right now we are using manual power for the cement mixer. I took the side mount plastic handle from a 120 volt hand drill and bolted it to the large mixer drum
pulley. It is surprisingly easy to turn. Even with a full load, my 11 year old son says it is just boring rather than hard to turn. At least now we can actually see our progress unlike when we were using a hoe and plastic mixing tray.

Thank you for all the comments,
Rob  



Re: New guy questions on generating power (none / 0) (#11)
by dozer on Tue Apr 6th, 2004 at 12:36:56 PM MST
(User Info)


Rob,

If they haven't shipped that motor yet, I'd cancel the order right away if I were you.

That's a high-speed / low-torque motor, and you need somewhat the opposite.  I would imagine your original motor is 1725 rpm, and probably has a 5/8" shaft.  The 5/16" shaft on that DC motor tells me it isn't a high-torque machine.

The "duty cycle" means that the motor is NOT robust enough to run continuously.  It will burn up if asked to carry a load for too long a time.  The "30 on 60 off" means that you must shut it off before 30 minutes, AND let it sit a minimum of 60 minutes before using it again.  I would think that with a cement-mixer, you'd want something rated to run continuously.

The Briggs won't use any more gas than you'd use running your car engine to keep re-charging the batt, if using a 12vdc motor.  You'll also avoid having to buy a new batt in a week... <g>  (car batts are not made for discharge cycling).

For free-to-$30, you should be able to find an old rototiller and get a Briggs from it.  That'd allow you to:

  • run as long as you want
  • vary the speed of the mixer
  • use the engine later for a genset, etc..
Look for an engine with a built-in governer (air-vane beside flywheel-fan, underneath starter-cover; with linkage rod coming out, which connects to throttle).

Genset from Induction Motor:  Yup, it works fine.  However, there is no way to regulate the output voltage except for varying the speed; so as you add load, you have to speed up the engine slightly, and your frequency will rise.  In the 3-5hp range, with a full load, you'll usually end up around 70hz. This won't bother anything....except clocks <g>.

As you remove load, the voltage will rise, and can get kind of high...130 or 140 volts...  Also, unless you've used a governed engine, the engine RPM will take off as the load's removed, causing the no-load gen. volts to go even higher.

You will need some AC-rated RUN capacitors.  Note:  RUN capacitors, NOT "start" capacitors !!!  The 'start' type will blow up after a few minutes of continuous usage.

I just uploaded a PDF file that I got off the web years ago.  You can go to my 'files' section of this forum and download it.  It has a wiring diagram and a graph for selecting capacitor values.  Gen-Induc.pdf

Note:  I have NOT verified any of his info.

Note:  If it was me, I'd use a 1750 rpm motor rather than a 3450 rpm motor.  With the Briggs running at 1800rpm, you'll get about half it's rated power....i.e. 2.5hp from a 5hp engine...but it'll use less gas per kw-hr and make a less grating noise.

I'd suggest spending some effort to locate a good junkyard, and make that your first stop, instead of harbor-freight.  Not a car-junkyard, but a real junkyard, with some of everything.  Some place that goes to the auctions when a big mill shuts down, etc. etc..  Such a yard is a GOLDMINE of equipment, parts, and materials !

At my local yard, I just picked up an alt/gen that looks like it was made for farm-usage, designed to mount in place of the regular alternator on an engine.  It's about a foot long and has BOTH a 45a/12v alt AND a 3kw 120vac 60hz genny built in.  Neat little electrical-machine.  Cost?  7 bucks!

Basically, a good yard of this type will sell you motors and xformers for just above copper-scrap price, which is around a buck a pound right now.  Saves them the trouble of tearing it apart to seperate out the copper.

In regards to running tools from an inverter, my experience has been that small angle-grinders and jigsaws run fine from a 1kw $249 inverter (i.e. Cobra et al); whereas a Skilsaw just slams it into shutdown <g>.  Oh, the big shop-vac runs fine on the 1kw too, but pushes the led-bargraph to the top.

We run our whole cabin from this type/size cheapy inverter, but I fire up a Monarch diesel-twin 5kw whenever I need to run the air-comp or the big 9" angle-grinder, etc..  I always try to time my work for when I'm going to charge the batt-bank anyway; which saves a lot of fuel and noise.

Hope some of this helps a bit...




Re: New guy questions on generating power (none / 0) (#12)
by dozer on Tue Apr 6th, 2004 at 01:15:22 PM MST
(User Info)


ps;

I just remembered a website I saw a few years back....a ham-radio guy who does a lot with little genny's...he's got a great page on making induction-motor genny's with little Briggs engines...

Also does engine-driven welders with Briggs and car-alt's, etc. etc..

http://www.qsl.net/ns8o/Induction_Generator.html


[ Parent ]



Re: New guy questions on generating power (none / 0) (#13)
by pumkindrvr on Tue Apr 6th, 2004 at 03:41:43 PM MST
(User Info)

Hi,
 That alt/gen makes my mouth water. :) Any chance you would part with it, or if you come across another? I would pay you a fair price.
 I know what you mean about finding good stuff in junk yards. When I lived in Penna, You could always find what you needed, often even at a car junk yard. Down here in El Paso, Tx. it is very hard to find even good car parts at a car yard. I think this is because there isn't much farming or other industry like up north and what ever does find it's way here ends up in mexico.
 I got a cobra 2kw/4kw inverter, used it once on circular saw to cut 2x4s. Next time I tried to use it, no power. Now I am waiting for paperwork to return it.
I will check out that site. It may be over my head. If not, I think I'd have better luck finding the Briggs on ebay.
 Thanks,
Rob



Re: New guy questions on generating power (none / 0) (#14)
by dozer on Fri Apr 9th, 2004 at 10:12:27 PM MST
(User Info)


yah, the wife sez my eyes lit up like halogens when I spotted it <g>.

I was planning on putting it in the local farm-shopper for $200, after I check it out thoroughly.  So far, I've pulled the end-bell checked the brushes and slip-rings (no detectable wear groove!) but I haven't actually spun it up and checked output, and under load.

Anyway, I'm not sure you want to pay that much, but if you do, let me know.  Heck, I might not be able to -get- that much; but I'm going to try to first.

It would cost quite a bit to ship.  Feels like a good 40 lbs ...maybe more.

I was originally planning on mounting it in my old F350, but it would've been a bear to make room for it....have to move the fuel/water sep, etc. etc..

Rob, for what shipping would cost you on a Briggs from ebay, you just -gotta- be able to find an old rototiller local !  I see them in the paper all the time for anywhere from "free, get it outta my yard" to 50-75 bucks.  Most are 5hp.

See that ham-radio site I left the link for.  He made an engine-driven welder from an 8hp and a 100a alt.  In your post about the pickup-loader, you'd mentioned getting a harbor-freight welder, but I was wondering if an engine-driven might be better for you.  You could use it anywhere, and wouldn't have to worry about house-wiring.  Those cheapy welders are crap anyway.  Only 10% duty-cycle, and junk controls.  If you do decide on a plug-in welder, get an old used Miller or Lincoln for the same 100-200 dollars.  You'll be glad you did.

Note:  the welder will only use house-current in proportion to the -welding- current you set and use.  So even a 200 or 300 amp welder could be run from a dryer-outlet....you just can't crank it up to full current.

The data the welder's panel will tell you the max current-draw....this is for max rated output current.  For instance, my 300a Miller draws 101 amps from 240v at full output.  If I only had a 50 amp dryer-outlet, I could run the Miller up to the 150 amp setting.  Actually, I'd probably only go to 130 or so.  No sense tripping the breaker every 2 minutes... <g>

Hope this helps...

 

[ Parent ]



Re: New guy questions on generating power (none / 0) (#15)
by pumkindrvr on Sat Apr 10th, 2004 at 09:20:21 AM MST
(User Info)

Hi,
 You are right, that is too rich for my blood and the shipping would be a killer. The money boss(wife) says it would just sit in garage with all my other projects cause I'm not the Mr. Fix-it I wish I was. :) She wants me to just buy a new gas generator that she found cheap on ebay. I think I'd rather spend the extra money and get a more powerful welder/generator. Years ago, I had a 220 volt  Lincoln welder that never let me down. As you can see, I'm torn between the do it yourself mode, where I tend to bite off more than I can chew, and just spending the money for something that I know will work.
BTW, good luck selling that generator. I hope you get what your looking for, that would be cool.
Rob



New guy questions on generating power | 15 comments (15 topical, 0 editorial)
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