Home made welder by day, DC generator by night
I took a Honda GC200 v belted it to an AC Delco DR44G alternator that I had upgraded to a much heavier "250 amp stator", external rectification provided by some used MRI machine parts and externally powered field excitation.
All I use it for is a welder. With the little GC200 engine it makes about 95 welding amps at 24vdc and makes a maximum of 87vdc open current voltage with 12v of field power wide open and 20v at idle. The alternator is over driven 1:2.
The crazy thing is it works really well, its one of the better DC machines I have ever used. I think because it's rectifying 1,000Hz 3 phase AC to DC.
Only problem is I would like to have more in the neighborhood of 120 to 130 welding amps for a lot of things and really 150 to 160 amps would pretty much do everything I would want a portable machine to do.
All I would need to do is add a voltage regulator to it and a bigger engine. I'm thinking about a 13hp engine.
If I were to go off grid I would most likely use a forklift traction battery, two 24v batteries in serries. At least 1,000 to 1,200AH, or as big as I can afford and still be able to move around.
I'm thinking it should be able to make 50 to 80 amps at 55v with out any issue and with out running it wide open.
Would as little as 50 amps help any for a pre morning bulk charge?
Because in the winter I normally get up 1 to 2 hours before sun rise and I could fire up the generator for a bit with a little fuel and leave it to run its self out of gas if I suspected the battery was real low or wasn't going to get a full charge off sun power.
Or should I go wide open, burn a lot more fuel and try to get close to 70 to 100 amps?
I think best fuel economy on these engins is some where around 2,200 to 2,500 rpm.
Solar hybrid gasoline generator, 7kw gas, 180 watts of solar, Morningstar 15 amp MPPT, group 31 AGM, 900 watt kisae inverter.
Solar roof top GMC suburban, a normal 3/4 ton suburban with 180 watts of panels on the roof and 10 amp genasun MPPT, 2000w samlex pure sine wave inverter, 12v gast and ARB air compressors.