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Topics - BruceM

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1
General Discussion / Batteries- Lead Calcium vs true deep cycle
« on: July 13, 2019, 04:56:21 PM »
My custom 120VDC battery charge management system was designed for 10- 12V AGM batteries in series, and has individual battery shunt regulators so that variations in batteries don't matter, and less equalization is needed.  I used cheap lead-calcium batteries (marine "deep cycle") initially for testing, and found that due to my very low average DOD, I was getting 4.5 years of service life. AGM batteries never came down in price so I've left well enough alone.  These Everstart (Johnson Controls) Marine batteries are stocked at the local Walmart.  They use so little water that I top them off annually, needing about a gallon of distilled water.  Low water use is one of the characteristics of lead-calcium.  They also have very low bulk taper charge characteristics similar to AGMs; as they become full, the charge current goes to well below 0.1 amps, typically below 0.050 amps.  This helps explain the lack of water use. 

I just added a T105 type (floor polisher battery - again "Everstart" by Johnson Controls though Walmart) 6V battery to my welder and am shocked at the difference in charge current.  The bulk charge current NEVER goes below about 2.2 amps, even if left on the charger, full, overnight.  I thought something must be wrong until I checked the Trojan data; they expect 2-3% of the C/20 to be the lower limit of charge current! 

I never fully technically appreciated the lead-calcium "Marine" batteries as I should have, since I was comparing them to AGMs and not wet lead true deep cycle batteries.  ( I use a 110AH AGM for my small 12V supply; I found 12 and 120V to be a very useful combination of home power). As long as you can keep your DOD below 20%, the lead-calcium seem to have good lifespan, good charge efficiency, very low water use.  They can also put out relatively high current, as I've found for the welder.   For my 120VDC system, currents are below 15A, usually well below that, which greatly improves effective capacity and efficiency.

It has been very educational to see how the T105 type 6V battery compares in a series application with the Marine (lead calcium) batteries.  While I have no doubt the T105 types will outlast them for the DC welder application, it gives me new appreciation for the Marine type batteries where DOD can be kept to modest levels for an expected service of 4-5 years.



2
Listeroid Engines / Propane Listeroid status- 1400 hrs
« on: June 17, 2019, 03:27:25 AM »
My neighbor with the propane converted DES CS clone just did an old change at 1400 hrs, last one was at 400 and it looked like it just came out of a new oil bottle.  At 1400 hrs today, he said it didn't look quite like new oil but it looked good.

The last 1000 hrs have been utterly problem free until my push rod kludge failed, and with the new welded extension to the push rod, he's back in action with full power again. So the keep to success for a propane CS is a CA110 carburetor, Garrett type regulator, and a hot spark module.  A special thank you to Gary at DES again for his awesome technical support on our conversion project.

I'm surprised there isn't a surge of interest in CS's for conversion.  ;)

3
Listeroid Engines / Propane CS clone power loss, welder fixed it.
« on: June 15, 2019, 11:17:21 PM »
My neighbor Jeff is the owner of the Propane modified CS from DES. He's been running it for the last 4 years with no troubles.  He mentioned he was having reduced power- couldn't carry both well and washer at the same time.  I suggested he check valve timing, as we had twiddled those to reduce exhaust/intake overlap to reduce propane smell in the engine room.  He did, and found that our extended push rod for the intake had failed. We had added 0.5 inches of aluminum spacer under the cylinder to reduce compression, so the longer exhaust rod worked fine for intake but former short exhaust needed a couple inches added. I had done weld bond kludge with some bits I had on hand; epoxied carbon fiber tube and added rounded end bit.  It had failed after 4.5 years, the carbon tube was now cracked as the ends pushed together, reducing the intake opening to only 4 mm from a normal 8mm.

I was thrilled to have a small welding project.  I had some rod of about the right diameter and welded on a new extension to the push rod. I used 7018 for the job, with some 6013 for finish filler.  It is very satisfying to have my new 24V battery welder put to good use, again. We installed it and reset the intake opening per the IO flywheel mark we put on (using 38AC's brilliant method), and now she's back to full power again.



4
General Discussion / Welding on clean DC
« on: May 25, 2019, 12:42:31 AM »
I bought a new group 29 "marine deep cycle" battery to give the clean DC, 24V welding thing a go. They are rated 385 cranking amps so a good match for 100+ amp welding current, and they are what I have in my 120V battery bank now.

I made a 600 uH choke from a gapped 1000watt laminated toroid core; 22 turns, 16 feet, of 6 strands of 12 awg. I gapped the core with a 10" abrasive chop saw blade in my table saw. I only lost 1/4" of blade on the job, but it took 4-500 gallon tanks of air to make the cut.  I filled the gap with steel filled epoxy. To save some $ on the trial, I used some heavy jumper cables for welding cables. 

The exciting news for me is that yes, I can do it. While regular welders have me running for the hills from EMI headache, this was doable for me.

Welding on 2-12V batteries does work, and as the article I found by a welding enthusiast stated, the choke makes it possible. When I bypass the choke, it's just not possible to maintain an arc and get the puddle going. Alas, I seem to be a bit lower voltage than I'd like- no such thing as long arcing with this setup!  7018 (3/32) rods were a bust, could not maintain an arc and liked to stick and melt the rod. 6013 (3/32) worked, best with positive on the electrode.  I'll have to set up some meters on volts and amps and get my neighbor to watch them while I do a practice bead.  I'm ordering some 1/8 rods- more current may have better arc length and stability.

I suspect the losses in the jumper cable are not helping, so I will pop for some fat and short welding cables.  I may also reduce the turns on the choke.  No need for that much inductance, but I goofed on calculations when shooting for 250-300uH.  Battery and all cables were cool immediately after a 6 inch test bead. 

I'm very rusty, my last stick welding was in 1974.  I think with some practice and some fine tuning of the setup, I can do my own welding again.

Yippee!


5
Generators / ST-3 is out
« on: January 22, 2019, 10:16:55 PM »
My ST-3 is out, won't operate on the harmonic winding system either, and flashing the FC dinn't change anything.  I did use the generator yesterday and it worked fine.  So far I'm baffled. The static (off) testing of brushes and slip rings looks good, field coil resistance is OK, harminic winding resisitance is OK, stator resistance winding is OK, my other various switches, fuses and relays OK.

Came in for late lunch, meds, and a study of the circuit diagram.  The bridge diode is a modern 800V unit so highly unlikely to have failed. I'll have to start using my handheld o'scope with a 15 foot extended probe lead and see what's gone wrong with the spinning harmonic signal while I stand outside.  It's cold, cloudy and windy.


6
General Discussion / snowed in, again
« on: January 13, 2019, 04:06:22 PM »
More cloudy and cold stretches this winter than we've had in 20+ years, and last night a forecast 0-3 inch now has turned into 8+ and still snowing this morning.  This just after the last snow finally melted.  I'll be on PV and solar hot water snow removal when/if it stops.  An alarming change after over a decade of milder, warmer winters (and hotter summers).   

Lucky for me a friend brought groceries 2 days ago. There's no county maintenance on our dirt roads here, it's DIY all the way.

11:30
Massive PV to the rescue.  With my additional 1500W, despite heavy overcast (though with snow on the ground assist) I've got plenty of power to charge.  By the time I finished shoveling snow, my main battery bank was up to bulk charge voltage. 



7
General Discussion / cold weather gear motor lube
« on: January 10, 2019, 07:13:30 PM »
I had a failure of the 5 rpm gear motor actuator which I use to control my projector focus.  Focus control is needed as the Qume Q5 focus is not temperature stable. it's a 24VDC rated little can type brushed motor I operate on 12V.  It stopped working when it got cold, even at 40F the motor would not start.  I use a modifed 2 channel IR receiver to control the gear drive, since I already have IR extender control of the projector.

I took it apart the failed gear motor and found the motor, brushes and commutator are clean, and the motor starts and runs freely at 12v in both directions.

So I'm thinking that the black grease which covers all the metal gears, and the worm drive which is on the motor shaft gets so stiff in the cold that the motor can't spin up.  Spin up is not aided by the two pole commutator. 

I'm thinking of cleaning out the grease and putting a bit of ATF on the gears.  I'm also going to boost the voltage.  I think there's some 19 or 21VDC for the projector I can use. This is not a high stress application and it only runs for maybe 30 seconds a day.  Any other ideas?

8
General Discussion / IDC connectors suck
« on: December 16, 2018, 11:45:10 PM »
I spent a few hours troubleshooting my remote fiber-cellphone hardware today. My memory is so poor it's a relearning project, though fortunately with pretty good documentation. The fiber-phone was a 2006 project, all hand soldered, no PCB, with a Picaxe M18 controller.  Ended up being one of the few Molex insulation displacement connectors I have left on that...on the 12v power to the solenoid that pushes the button to turn on the cell phone.

I never use Molex IDC connectors anymore, for good cause.  The contact to the wire is just not reliable over time. 

Not much fun working in the cell phone dog house when you're having a bout of Graves and your heart is going 100 BPM and your hands are shaking. 




9
Everything else / DIY Low EMF 5 step Sine Inverter
« on: July 29, 2018, 03:12:30 AM »
I thought I should play nice and quite stuffing this in Glort's PV -grid tie work.  While I did add 1500 watts of panels to my existing 875 for this project, I'm now down to the inverter work.

A little review:

I live off grid and have lived with my own 120VDC system and Listeroid for AC and compressed air for a long time.  In preparation for adding inverter power to my system, I upgraded my 120VDC PV charge regulator to handle up to 3000 marketing watts of PV.  It's linear, not pulsing, for very clean DC.

My 120VDC input inverter design is based on the venerable Trace SW series which does low frequency switching of transformers with secondaries in series to create a sine.  That general concept is about all I'm using.  I'm using very soft (slow) switching plus snubbers and minimal passive filtration to generate AC with no audible (via AM radio) EMI on the AC or DC supply.  I'm only using 2 transformers of equal output secondaries, and they are used to make a 5 step sine wave; zero plus two steps up and two steps down.  I originally did a 7 step sine but found 5 step better. The 5 step sine gets the THD down below my ST3 generator head, and eliminates the typical 20% motor heating loss of a MSW inverter.  I use 120VDC for my home and shop power, and have been using a Listeroid 6/1 for AC generation for well pumping and washing machine.

I have previously done quite a bit of testing of the prototype on motor starting at 120VAC output; it would start a 1.5HP tile saw like grid power, instant and effortless.  I ran into a bunch of trouble when I switched transformers for 230VAC output; ultimately I tracked it down to huge inrush surge current.  Until I worked up a software solution of soft starting the transformers, I could only test by starting the processor and H-bridges with 0 volts input, then switching on the 120VDC through two huge chokes and 30K uF of DC filter caps. This provided a slowly increasing voltage which kept inrush current minimal. The massive DC filter was needed for keeping AC off my clean 120VDC. With the filter in place, I now have 1 millivolt of AC ripple with 1000 watts of load.  Backfeeding 230VAC to my step down transformer outside the shop, I've run a couple loads of laundry in the washer (about 1100 watt load also) with no trouble and barely warm heatsink on the H-bridges.  I've also been testing with 500, 1000, and 1500 watts of heat lamps in the shop.

I got the prototype jury rigged on the floor of the battery bank shed and then found that due to my new short 120VDC supply wires to the 10K uF fiter output capacitor, the old Antek transformer inrush current problem came back and bit me.  I should have tested with small fuses, but I got cocky...with 4 mosfets, 3 ICs, and 2 transistors fried the result.  I got it repaired, changed the soft start to extend from 50 usec to 5 millisecond pulses, and now she starts and stops nicely on small fuses, again.

Tomorrow I'll test on my 1/2 HP Franklin submersible well pump. It pumps from a depth of 200 feet.  It normally runs at 1150 watts, with starting peak over 3400.  The issue to be tested will be surge load capability and compatibility with the operation of the Franklin QD solid state capacitor start relay.


10
Listeroid Engines / Icreasing rpm of 6/1 with SOM flywheels
« on: January 11, 2018, 02:35:02 AM »
I'm thinking of leaving my 6/1 on diesel for now instead of doing a propane conversion.  My new SOM wheels are 25  inch diameter so I must increase the ST-3 pulley size.  Since it worked out well for my neighbor's machine, I'm going single B belt.

At the same time, I'm considering a modest increase in RPM- say to 700 (ish) rpm.  This will benefit my air compressor which was being driven well below it's max rated speed. 

Are there any hidden surprises I should be thinking of?  My 6/1 has the iron piston.  Adjusting counterbalance weights on the new SOM wheels for a smooth run isn't be a big deal for me.

The B belt riding flat on the flywheel gives it an effectively large diameter compared to belt on the pulley vee shoulder.  So 1800 rpm at ST3 over the pulley ratio of 25.6"(SOM flywheel effective dia with B v-belt and no grooves)/10 (pulley size at ST3) gives me 1800/2.56 = 703 rpm engine speed.  A 10.25" pulley should give me 720 rpm. Either would be OK for my air compressor speed with existing 19" drive pulley.

Any helpful thoughts or gotchas I'm missing?







11
Listeroid Engines / SOM flywheel upgrade!
« on: October 19, 2017, 02:06:40 AM »
Thanks to 38ac I got connected with another member Robert Leonard, who had some SOM flywheels for sale.  Bob did a great job of securing them to a sturdy pallet and getting them loaded on my freight carrier 8 days ago.  Today I picked them up at my local helpful Ace Hardware.

They are now on my shop apron ready for some clean up and new paint! They are a bit shocking to a someone only familiar with Rajkot castings; there are no voids, putty, bondo!

I'd like advice on your favorite rust treatment that does not involve Rustoleum type oil based paint.  I just can't stand the stink of it. I'm thinking sand and wire brush, naval jelly, then paint. I'm in AZ, USA, so continued rusting is not a big issue, I'm just proud of them so want to pretty them up a bit.




12
Generators / CGG ST heads- warning- aluminum windings
« on: August 24, 2016, 02:09:32 AM »
Dear friends,
We recently had a open circuit failure of one rotor coil winding of an ST-3 head from Tom at CGG.  Since he didn't have a replacement coil, we ordered the matching 19 awg magnet wire and after winding it found the resistance didn't match, and it was much heavier. Checked closely and found that the windings in this year old ST head are ALUMINUM.

I'd also like to add that the windings were not redesigned for aluminum; they are the same 19 gauge as the copper in my older ST-3.  The copper windings are 4.3 ohms per coil, these are almost 7 ohms.  I'll be checking the stator windings later today, but I expect the same was done there.  Visually they look identical, which was not doubt the intent. 

I'm now looking for an all copper ST head replacement.  Does anyone know of a reputable importer of all copper ST heads? If I'd known this thing was aluminum I would never have recommended it.

Thanks,
BruceM

13
Generators / Frequency/Voltage Meter for ST gensets
« on: April 14, 2016, 04:12:39 PM »
I've been disappointed with the analog panel meters for AC frequency and voltage from China.  The frequency meters in particular are junk- when voltage goes down (with increased load and thus lower frequency), the frequency meters show an increase in frequency! Laughably bad design.

Many digital frequency meters have problems with the ragged waveform of the ST generator heads.  They will not display the proper value, or even close.

I did find one cheap ($10) digital meter that is quite good:

http://www.ebay.com/itm/131683950915?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Both frequency and voltage are displayed properly and accurately on an  ST-3 head on harmonic.  Voltage is RMS, tracks a Siemens ($) display within a volt.






14
Generators / CGG AVR- not so hot for non-linear loads
« on: March 23, 2016, 02:15:41 AM »
Hi Guys,
We're using the CGG AVR on my neighbor's ST-3 with propane converted DES 8/1.  It is using the Harmonic winding as the excitation source, since it just doesn't work at all using one leg of the line voltage (can't start even a 1/2 hp motor).  Tom lists that configuration, but frankly, he should not.

On the harmonic the CGG AVR works fine on induction motor loads, but on non-linear loads like a small wire feed welder, or a Vitamix on (electronic controlled) low speed,  it regulates the voltage so low our RMS voltage monitor trips. (regulates to 170V RMS instead of 240, and 85V on the stepped down 120V supply).  On straight harmonic the ST-3 does fine on these same loads.

So alas, while Tom's price is appealing, the AVR being sold by CGG has some serious limitations:

1. You can use it only with the harmonic winding for excitation.  
2. It regulates only to peak AC voltage levels, not RMS,  and will down regulate to grossly low voltage for some non-linear loads.

Can anyone suggest a 240V AVR that does a decent job of regulation?  Something that says "RMS" voltage in the specs perhaps?


15
Listeroid Engines / Mechanical water pump ideas?
« on: March 20, 2016, 03:15:55 PM »
We've found that my initial design for cooling, thermosiphon for coolant flow and thermal chimney for air through the radiator is inadequate for extended runs at full load.  From some experiments with increasing the stack height and modest fan on the radiator, it seems our water flow is inadequate.  We are getting 54 degrees of cooling on the return water, but still engine temperature very slowly climbs. Raising the radiator more would do it but then our thermal chimney for the radiator gets even taller, which is a structural issue for high winds.

I'm looking into options for a water pump. A mechanically driven by a rubber roller or vee belt off the flywheel would be lovely; it could also let me lower the radiator, increasing the vertical for the thermal chimney.  Any suggestions on a suitable pump and how to do the bypass so that a thermostat could continue to be used?  

Alternately, can someone suggest a suitable AC pump?  

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