Can we create a Forum for aircooled Diesels?

[90cummins]

My Yanmar 24 volt generator project.

Yanmar Project
This is my most recent Yanmar project.
The engine is a Yanmar L100 that I completely rebuilt with a new OEM crankshaft, piston & rod.
It is driving a new Niehoff N1603-2 28v 450 amp alternator.
I built it to support my off grid battery pack.
I built the frame using 1/4" steel and bent the angles on my 40 ton press.
I used bolts for assembly because it allows me to easily change/modify the design.
The engine is turning 2700 rpm which is the sweet spot for minimum fuel consumption.
During testing I found that it would run 5+ hours with a 1kw steady state load with the ability to handle a much higher surge when connected to my 24v 370ah battery pack that powers my 4kw inverter.
Running the engine at maximum speed 3600 I can pull 200 amps of DC current.
The crankshaft is tapered for generator use but I used a bushed bore pulley so I could belt drive the generator.
Overall I'm very pleased with the performance and will be adding a low oil pressure shutdown.
I would like to add an external governor that would adjust the engine speed according to the load.
This summer I plan on building an insulated & power ventilated enclosure to shelter and control noise.

 

[TomSeller]

An L100 is a 10 HP thumper. Impressive. What happened such that it needed a rebuild? My Yanmar air cooled is a 6 HP model and runs and starts strong.

 

[90cummins]

An L100 is a 10 HP thumper. Impressive. What happened such that it needed a rebuild? My Yanmar air cooled is a 6 HP model and runs and starts strong.

I bought it as is so I don't know any details.
It was a mess. It was run out of oil so the crank & rod were blue but the cylinder was not damaged.
I bought it to use for parts on my L90 but ended up rebuilding both the L90 & L100.
My L90 is being used on a pressure washer.
I have a total of 4 Yanmars
L100 with generator crank
L90 with generator crank
L70 driving a 5kw generator head. This engine I bought new because it had an extended 3qt sump with a bypass filter that allowed it to run over 400 hours unattended.
3kw Yanmar generator with an L60 that is currently not running.


90cummins

 

[90cummins]

L70 Yanmar generator & Farymann Diesel APU

Here are two of my other generators;
The first is an deep sump L70 Yanmar with a bypass oil filter for extended non stop running.
I have it mated to a 5kw generator head that allows stable voltage output until the engine speed droops due to excessive load.
The over sized gen head provides excellent surge capabilities while the L70 minimizes fuel consumption.
My other generator is an MEP-952b 28v Military APU that directly supports my 370ah 28v battery backup system.
It is rated at 5kw continuous and is powered by a Farymann 43F diesel rated at 15hp.
During testing I pulled 200 amps but my cables and battery connections were getting hot so I shut it down.
I replaced by battery to battery 4/0 cables with copper buss bars which solved the heat at the battery now I need to increase the 1/0 cables to 4/0 to eliminate the cable heat/voltage drop.
It is enclosed in an armor plated enclosure and is sound attenuated which makes it very quiet.
it has provisions for a hand crank starter if the battery or starter fails.
It is fully protected with low oil pressure and over temp controls.
Sorry for the off kilter photos
90cummins

 

[90cummins]

I have 2 Military surplus MEP-952b 28v DC APU's 1 of which is being used to support my battery backup system.
These units use a German made Farymann 43f diesel engine rated at 15hp to drive a 280A DC generator.
I'm looking for anyone with knowledge that can help me modify the governor for steady state operation at 2000 rpm from the original 3000 rpm.
Another option would be to information to build/install an electronic variable speed control system.
The reason is to reduce fuel consumption when being used for battery support at lower power levels.
At less than full throttle operation the governor allows excessive droop when a load is applied.

Any information would be greatly appreciated;

Thanks 90cummins

 

[90cummins]

I would like you to check out my DC generator that I built to charge my battery bank for my 4kw home inverter when the power is out.
I bought and rebuilt a 10hp Yanmar L100 diesel that I bought off Craigslist and use it to power a 28v 450 amp Niehoff N1603-2 DC generator to support my 24v off grid inverter.
I have the engine turning at 2750 which is the sweet spot for minimum fuel consumption & peak torque and the alternator is turning at 1450 rpm. Run time with a 1kw AC load is 6hrs per gallon.
The frame is made of 1/4 steel and I used bolts rather than welds so I can easily modify it.
I could use some help in a couple areas.
One is making or selecting a device to adjust the engine speed as the load increases.
Another area I need help with is a way to adjust the output voltage from 28.6v to 27.5v.
I have the manual and engineering drawings if that is of any help.
At 28.6v the generator is constantly pushing a charge into the batteries even when they are charged.
When a high load is turned on the generator attempts to carry the load because the battery float voltage is lower than the charge voltage.
Reducing the charge voltage will allow the batteries to share the load rather than allow the generator to carry it.
I'm thinking that I could adjust engine speed using current as a reference, but I have no idea how to do this.
The generator also has an AC output for use as a speed reference if that is of any help.
I have a video on YouTube I think you will enjoy.
Thanks 90cummins


Yanmar 1hp Diesel DC backup Generator - YouTube