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Old 06-19-2019, 02:21 PM   #1
Midwestdrifter
 
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Default DC Generator Kit

I saw this over on expedition portal. Appears to be a kit which allows connecting a small gas engine to a common alternator. With external regulator it could very quickly charge a battery bank. Seems like a good approach for DC only off grid systems.

https://www.affordabledcgenerators.com/
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Old 06-19-2019, 02:41 PM   #2
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Default Re: DC Generator Kit

Interesting kit and small too!

Have seen the homebrew belt driven units but they wind up taking up a lot of room.

https://gooddebate.org/sin/mirror/li...d_your_Own.pdf

For the DIY version, one of the challenges is finding an alternator with the proper fan rotation to get the alternator on the same side of the belt as the engine. This fan can help that:

https://www.ebay.com/itm/Rare-Bi-Dir...MAAOSwig9dA6uQ
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Old 06-19-2019, 02:51 PM   #3
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Default Re: DC Generator Kit

The Honda GC160 is rated at 3.4kw output at ~3500rpm. So in theory it should support a larger alternator. Though you may need to ramp the throttle up before connecting a larger load. At 75% efficiency, that is 2.5kw, which is a fair bit above the 1.7kw the suggested alt supplies.

What that kit really needs is an electric start. It would make a good backup unit for off-gird lithium systems. Of course then you get into extended fuel tanks, oil level monitoring, etc. At which point maybe retrofitting a larger commercial unit may be worthwhile.
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Old 06-19-2019, 03:11 PM   #4
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Default Re: DC Generator Kit

Too bad there isn't an easy way to use the alternator to start the engine.
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Old 06-19-2019, 03:14 PM   #5
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Default Re: DC Generator Kit

Maybe someone should design/find a cheap starter generator? My EE knowledge is small, but auto alternators aren't wound right for that purpose?
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Old 06-19-2019, 03:20 PM   #6
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Default Re: DC Generator Kit

Could easily do it with one of the old VW brush/commutator generators - but then you lose all the advantages of the alternator. Would probably need a compression relief until it got some speed up.

You are right - an alternator is fairly close to being a stepper motor - but just too many differrences to easily go those final yards.

Last edited by rollerbearing; 06-20-2019 at 01:40 AM.
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Old 06-19-2019, 03:51 PM   #7
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Default Re: DC Generator Kit

link to thread https://www.expeditionportal.com/for...erator.206366/
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Old 06-19-2019, 05:03 PM   #8
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Default Re: DC Generator Kit

Cool product. Nothing earth shaking but an easy path to a an inexpensive and ultimately user-serviceable homebrew unit, got to love it. Here is a lot of info on the Delco 10si/12si series with comments on proper cooling.

http://www.madelectrical.com/electri...elcoremy.shtml
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Old 06-19-2019, 11:00 PM   #9
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Default Re: DC Generator Kit

For the DIY savvy, you could rig up a spare sprinter alternator. Different mounts required, and the pulley would need swapped (either on the alt or engine).

Combined with an external regulator, and you got some interesting options as well
https://sterling-power.com/collectio...tor-regulators

Though a simple diode mode would get the 12si up to absorb/equalize range.
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Old 06-20-2019, 01:13 AM   #10
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Default Re: DC Generator Kit

A likely far more pricey commercial package version:

https://ironedison.com/images/produc...r_brochure.pdf

Whoooo Boy! About $1800 for something similar to the kit -

https://www.altendc.com/

Last edited by rollerbearing; 06-20-2019 at 01:26 AM.
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